PROCESS INDUSTRY

Less input. Same quality. More output.

Cut your cost with real-time process optimization.

Powered by Causal AI

Avoidable Costs in Everyday Operations

Many process lines run below their potential. Gaps in real-time quality visibility are covered with oversized safety margins; conservative set-points and manual tuning drive up raw material and energy use.

  • Limited on-line visibility
    Key quality metrics arrive late or not at all during production.
  • Stacked safety margins
    Operators bias settings heavier/slower and hotter to stay within spec.
  • Inefficient set-points
    Non-optimized conditions increase energy consumption and wear.

Together, these issues add hundreds of thousands—often millions—of euros per line each year.

The good news: smarter guidance and control can cut variable costs significantly.

Why Optimization Remains Out of Reach

Even with modern systems and seasoned crews, balancing quality, throughput, energy, and safety is tough. Three root causes keep most lines below their potential:

  • Delayed off-line measurements
    Critical quality metrics arrive late and too sparsely for real-time correction.
  • Safety-margin bias
    Limited visibility drives heavier/slower/hotter set-points to stay within spec.
  • Tight process coupling
    Speed, temperature, and pressure are often closely interdependent—small adjustments can impact product quality, making operators hesitant to deviate from proven (but suboptimal) settings.

Without sharper visibility and actionable guidance, even skilled teams can’t close the control gap—so variable costs creep up shift after shift.

How PBX Closes the Control Gap

PBX brings intelligence directly to the line—analyzing live data, predicting outcomes, and guiding operators in real time. The result: stable quality, lower resource use, and more confident decisions.

  • Real-time visibility and guidance
    PBX uses soft (virtual) sensors to estimate key quality metrics in real time. It delivers clear, actionable guidance so deviations are corrected before they become losses.
  • Smarter control of key levers
    PBX continuously aligns process settings to make better use of available input—improving efficiency while keeping quality within spec.
  • Safe, validated adjustments
    PBX supports operators with clear recommendations, expected outcomes, and built-in guardrails—enabling safe, routine optimization even in complex, interdependent processes.

PBX turns routine decisions into real savings—closing the gap between actual and ideal performance.

Why Process Booster X is Your Ideal Choice

PBX brings true intelligence to production — not by adding hardware, but by understanding how each process behaves. It continuously learns, predicts, and acts to keep quality stable and resource use minimal.

Causal Line Model

PBX learns the real cause–effect relationships of your line directly from raw data — requiring only minimal expert input.

Real-Time Actions

PBX turns live data into real-time actions that maintain output and quality while while cutting energy and resources use.

Copilot or Autopilot

Start with recommendations for operators; move to automatic execution within guardrails once confidence is built.

What Processes Can Expect with PBX

PBX directly improves process efficiency and stability — not through new equipment, but by optimizing how existing systems are controlled. The impact becomes visible within weeks of operation.

Material savings

Improved visibility and real-time guidance reduce safety margins and cut avoidable material overuse.

Energy savings

PBX optimizes the entire process based on a holistic understanding of energy drivers—maintaining quality and output while minimizing consumption.

More Stability

Tighter to spec, faster recovery after changes, fewer deviations, and less waste or scrap.

High Speed to Value

Preliminary analysis in 2 weeks • first line productive in 3 months • ROI within the first year

Get started

We offer a free preliminary analysis to quantify potential savings for your specific lines. Before that, we’ll start with a short discovery call — to align on goals, data availability, and what matters most for your mill.

STEP 1

Discovery Call

(60 min)

We discuss your production setup and challenges and align on where PBX can create the strongest impact.

STEP 2

Preliminary Analysis

(Results in 2 weeks, free of charge)

You share historical production data (under NDA). We evaluate data coverage and quality, and provide first actionable insights - check out our data requirements.

STEP 3

Result & Next Steps

(Decision gate)

We share the quantified potential and discuss suitable next steps - pilot, scope, and timeline.

Ready to see what’s possible on your lines?
Request a discovery call with our experts to discuss your potential.