Tie the dose to quality
Real-Time Prediction ties the dose to where quality is heading, updated every 30 seconds.
Real-Time Prediction →Stop paying for raw material your process doesn’t need.
Chemistry, fiber, polymer and resin are set for the worst case because quality is confirmed late. ProcessMiner ties each dose to where quality is heading, so you cut the extra without putting quality at risk.
Read the transcript
An alert tells you something’s wrong. Not what to do. So every shift estimates the correction from memory. PM Vector puts your best run for this grade on screen as a live target. When a variable drifts, operators see the exact setpoint to move to, on levers they control. The target retrains as you run, so your best crew’s settings become every crew’s standard.
Where the material goes
Every crew doses for the worst case. Your input budget pays for it.
Underdosing shows up immediately, so overdosing becomes the operator’s safe default. Giveaway above spec spends fiber, polymer or resin the customer never pays for. Scrap and off-spec product spend it twice.
25%
Less wet-strength chemistry
One paper machine, 12 months
13% → over 20%
Sludge cake solids
Wastewater dewatering pilot, no added polymer
25%
Scrap-rate reduction
Injection molding, single-machine pilot
Single-deployment and pilot results, each measured against that plant’s own baseline and labelled with its industry. Results vary; past performance is not a guarantee of future results.
How it works
3 steps to dosing for what the process needs
Hold your best run
PM Vector holds dosing and setpoints at your best run, grade by grade.
PM Vector →Automate when you’re ready
Autonomous Optimization can automate the dose within limits you set. Open loop comes first.
Autonomous Optimization →~1,600 lbs of chemistry saved in one week on one paper machine, with closed-loop control on 32% of the time.
PM Vector: your best run vs. the live run, with the setpoint to move. See PM Vector →
By industry
Where the input lever sits in your plant
Pulp & paper
Chemistry and fiber are the levers. Fiber is ~50% of production cost (industry benchmark).
~$1M cumulative savings, one paper machine, 12 months
Nonwovens
Basis-weight giveaway spends polymer, the largest single line in a nonwovens line’s cost of manufacture.
Plastics
Every scrapped part throws away its resin, so cutting scrap cuts the resin behind each good part.
Free Data Health Assessment
Find out where your inputs have 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
How is this different from a supplier's dosing program?
A supplier-set or manual dosing program sets the dose for the worst case and revisits it when the contract does. The overdose in between shows up only in the chemical budget. ProcessMiner ties the dose to a live, grade-specific quality prediction and holds it at what the process needs now, retraining on every new lab value.
Won't cutting chemistry put quality at risk?
The dose is tied to the quality prediction, so it comes down only where the model shows quality holding. When the trend heads toward a limit, the recommendation moves the other way. In the same case that cut chemistry 25% on one paper machine, target adherence improved 63% against the operator baseline.
How much can we expect to save?
On chemistry across pulp & paper deployments, about 25% is the proven ceiling and 10% the conservative floor. The free Data Health Assessment shows where your process has room to come down. You put the value on it with your own costs.
Get in touch
Have a question?
Whether it's our platform, your process, or a free Data Health Assessment you'd like to start, let us know.