See where it’s heading
Real-Time Prediction shows where the process is heading, so crews correct early and carry less margin.
Real-Time Prediction →Energy is a process variable. Control it like one.
Drift shows up as more air, steam and pumping, at rates set for the worst case. ProcessMiner lets energy follow what the process needs, with your operators in control.
Read the transcript
Your process data is already telling you what’s wrong. The problem is hearing it in time. ProcessMiner sits on the historian you already run and shows where quality is heading, for the grade you’re making. It ranks what’s driving a deviation, and recommends the setpoint to move to. In open or closed loop, your operators stay in control. One platform, on your own data.
Where the energy goes
Variability is an energy bill nobody itemizes.
When the process drifts, crews compensate with more air, steam or pumping. Blowers, pumps and drives often run at a fixed rate set for the worst case. Off-spec product spends the energy twice.
>50%
Of a wastewater plant’s energy goes to aeration
Industry benchmark
20–40%
Less aeration energy with demand-tracking blower control
Industry range
13% → over 20%
Sludge cake solids
Wastewater dewatering pilot, no added polymer
Fewer wet tons trucked and dried
The aeration figures are industry benchmarks, not ProcessMiner results. Cake solids are from one wastewater pilot, measured against that plant’s own baseline. Results vary; past performance is not a guarantee of future results.
How it works
3 steps from a fixed rate to following demand
Hold the efficient point
PM Vector holds the efficient operating point found in your best runs, shift after shift.
PM Vector →Automate when you’re ready
Autonomous Optimization lets air or dosing follow demand on levers you choose, within limits you set. Open loop comes first.
Autonomous Optimization →By industry
Where the energy lever sits in your plant
Water & wastewater
Aeration and dewatering are the biggest energy levers. Blowers commonly run at a fixed rate regardless of oxygen demand.
Pulp & paper
Steam and drying energy follow variability. Holding the sheet at target is the lever.
Plastics
Cooling is usually the largest part of cycle length. Shorter, steadier cycles mean less energy per part.
Free Data Health Assessment
Find where your energy has room to come down.
Start with a free Data Health Assessment. We’ll take a closer look and let you know exactly what your own data can do.
Needs 6–12 months of process history with timestamped lab results.
Questions, answered
Frequently asked questions
Where does the energy saving come from?
From variability. Every drift away from the efficient operating point is compensated with more air, steam or pumping, and every off-spec run spends energy twice. Holding the process at target removes that compensation. Wastewater aeration is the clearest case: it takes more than half of a typical plant’s energy (industry benchmark), and in one dewatering pilot sludge cake solids rose from 13% to over 20% with no added polymer, so fewer wet tons were trucked and dried. In paper, we don’t publish a separate energy percentage, and won’t until one is measured.
How is this different from an energy-efficiency program or EMS?
An efficiency program buys a better blower, VFD or heat-recovery project and books the savings once. An energy management system (EMS) meters and reports consumption. Neither changes how the process runs hour to hour. ProcessMiner works on that operating layer, holding the process at best-run targets every shift. The two fit together: the EMS measures the savings, and the platform helps produce them.
Can the platform control aeration blowers directly?
Yes, through the VFDs already on your blower motors, when you choose closed loop. Every deployment starts in open loop, with recommended setpoints your operators verify. Blower control moves to closed loop only on the variables and hours you authorize, and your operators can switch it off from the floor at any time.
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Have a question?
Whether it's our platform, your process, or a free Data Health Assessment you'd like to start, let us know.