Reduce quality variability
See quality drift as it starts, not after the lab confirms it. Hold the process closer to target, run after run, so quality stays consistent instead of swinging between the guardrails.
Cut chemistry use by up to 25%. Seen in specific deployments.
Chemistry is the fastest cost lever on a continuous line, and overdosing is the default almost everywhere. ProcessMiner replaces dose-by-instinct with precise, quality-prediction-driven setpoints, so the savings show up on the ledger, not just the dashboard, and less chemistry used means less chemistry discharged.
Where the money leaks
Overdosing is the safe default. It's also the expensive one.
When the penalty for underdosing is immediate (off-spec product, a customer claim), operators add margin to every dose. That margin, repeated shift after shift, is a six-figure line item on most machines.
Before / Manual dosing
Dose by experience, err on the high side
Operators set chemistry manually, using experience and the last lab result.
- Overdosing as insurance. The cost of underdosing is visible; the cost of overdosing is buried in the chemical budget.
- Lab-lag adjustments. Doses change only after a result comes back, hours behind the process.
- Shift-to-shift drift. Each crew doses differently; nobody sees the aggregate cost.
After / ProcessMiner
Precise setpoints, recommended or automated
The platform ties dosing to real-time quality predictions, holding chemistry at what the process actually needs.
- Quality-prediction-driven dosing. Quality predicted every 30 seconds; setpoint guidance issued every 15 minutes, only when needed.
- Quality protected. Doses come down while grade/SKU-specific quality limits stay enforced.
- Recommended or automated. Start with operator-approved setpoints; automate dosing when your team is ready.
How the savings are produced
Three capabilities, one line item going down
Chemistry savings aren't a module you switch on. They come from setpoints held on target, dosing automated within limits you define, and models that keep learning as your process changes.
01 / Intelligent Centerlining
Hold chemistry at the golden-run setpoint
Centerlining identifies the setpoints from your best production runs, chemistry dosing included, and keeps key variables aligned to those targets in real time. The waste margin operators add for safety is exactly what centerlining removes.
- Chemistry setpoints tracked against golden-run targets on a live dashboard
- Up to 63% better target adherence versus operator baseline, in specific deployments
- Grade/SKU-specific targets applied automatically through product transitions
02 / Autonomous Optimization
Automate the dose, keep the operator in control
In closed-loop mode, the platform writes precise chemistry setpoints directly to your control system within boundaries you define. One deployment saved roughly 1,600 pounds of chemistry in a single week while running autonomous just 32% of the time.
- Adoption path you control: open-loop recommendations first, then limited closed-loop (1–2 hours a day), then expanded (8+ hours), then full autonomy
- Operators toggle off during grade/SKU transitions and re-enable after stabilization
- Savings scale with autonomous hours; you set the pace, not the platform
Autonomy adoption path
03 / Adaptive model retraining
Savings that hold as your process changes
A dosing model tuned once decays as furnish, equipment, and grades/SKUs shift. ProcessMiner retrains continuously with every new lab value, testing hundreds of modeling approaches and keeping the best fit live, so the chemistry reduction you earn in month one is still there in month twelve.
- Models retrain on every new lab result, automatically
- Auto-switches modeling methods when performance degrades
- Quality predicted every 30 seconds, so dosing never runs blind between lab tests
Cumulative savings, single deployment
Why chemistry is the fastest lever
STOP OVERDOSING CHEMISTRY AND START SAVING COSTS IMMEDIATELY.
Fiber accounts for roughly 50% of paper production cost, and most of it is locked in by markets you don't control. Chemistry is different: it's a variable cost your operators set every shift, which makes it the fastest place to take cost out. A 10% chemistry reduction can represent hundreds of thousands of dollars in annual savings in specific verticals, and the same dosing logic extends to other consumables the platform can hold on target.
Optimize for what matters
Improve quality, cut chemistry and energy waste, and lift throughput — the outcomes that show up on the bottom line. ProcessMiner turns your process data into the specific moves that get you there.
Built on your team's expertise
You know your equipment and your product. ProcessMiner brings the process intelligence and puts it directly in your operators' hands — no coding, no rip-and-replace. Speed to value, built on the knowledge your team already has.
Results from the field
The numbers behind the claim
25%
Wet-strength chemistry reduction
Pulp & paper deployment
~1,600 lbs
Chemistry saved in one week
At just 32% autonomous mode
$1.5M
Cumulative savings in 12 months
Single deployment
$2.4M
Value per machine, per year
50% attributed to the platform
Figures reflect actual ProcessMiner deployments in pulp and paper. Results vary by facility, process, and data quality; past performance is not a guarantee of future results.
Prove it on your data
Find out what 10% is worth on your machine.
We'll look at your chemistry spend, your grades/SKUs, and your historian data, then show you where the savings are before you commit to anything.
~30 min
to connect your historian
Hours
to a first live quality prediction model
Under 2 weeks
to full deployment
Get in touch
Have a question?
Whether it's our platform, your process, or a free in-depth process data analysis and pilot you'd like to see in action, let us know.