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Equipment fouling is a common operational challenge in manufacturing environments. Fouling can lead to major economic consequences due to increased operating costs and decreased productivity associated with the unplanned shutdowns required for frequent cleaning. Equipment performance is reduced when unwanted material accumulates on the solid surfaces of heat exchangers, furnaces, pipes, reactors, etc.  A fouled [...]

Empowering Dow Chemical to fill the demand for low-volume, high-urgency orders of custom specialty chemicals using ProSensus’ RPD framework.

An emulsion polymer process was producing off-spec product in 10% of its batches. By implementing advanced batch control, they were able to completely eliminate the bad batches.

ProSensus worked with Mondelez, a global food manufacturer, to establish specifications on new incoming raw material lots to avoid accepting lots that pose a high risk on the final product quality.

Specifications on individual properties are often misleading. ProSensus calculates multivariate specification limits so you can accept/reject and compensate for variations in raw materials. Read about examples in the chemical, pharmaceutical, and food industries.

By implementing ProSensus’ ProBatch Control technology, a leading snack food producer reduced the standard deviation on their product quality 50% and also significantly increased process capacity.

By implementing ProSensus’ ProBatch Control technology, a leading snack food producer reduced the standard deviation on their product quality 50% and also significantly increased process capacity.

ProSensus helped optimize a Fortune 500 pharmaceutical tablet manufacturing line, providing a method to reduce the time needed to respond to changes on the line and improve the final product quality.

A herbicide manufacturer was producing many out-of-specification batches in their batch dryer. Multivariate analysis was used to troubleshoot why unacceptable chemical structural changes were occurring.

Scaling production from lab-scale to full scale can be time consuming, frustrating and costly. An effective alternative is to apply numerical optimization on multivariate models that span both scales.

ProSensus helped integrate state-of-the-art multivariate calculation tools into Johnson & Johnson’s in-house software so that multivariate analysis could become part of their standard data analysis workflow.

Irving Pulp & Paper chose ProSensus to create a soft sensor to stabilize their lime kiln process. Using real-time process measurements and images from a camera in the kiln, ProSensus developed a soft sensor that predicted kiln temperature hours in advance.