Two products, one goal: keep PID loops and APC strategies accurate and correctly tuned. Each targets a different layer of process control optimization, and plants often deploy both together.
Multi-objective PID tuning and PLC- or DCS-resident advanced process control (APC) design and optimization, performed in the time domain from existing closed-loop data. PITOPS can also improve the performance of third-party model predictive control (MPC) systems such as PACE from Yokogawa, RMPCT from Honeywell, SMOC from Shell, and DMC from AspenTech.
AI-based, fully automatic, auto-adaptive online PID auto-tuning that optimizes tens or hundreds of loops simultaneously, on the fly, without changing any loop's mode between Manual, Auto, Cascade, and Program. SUPERTUNE tunes ramped, integrating, and self-regulating processes alike.
Process control optimization is the set of techniques and technologies that maximize plant efficiency, ensure consistent product quality, and improve control reliability. It rests on two connected principles: control system enhancement, adjusting the PID settings and advanced process control (APC) parameters that determine how a process responds; and data-driven insights, using plant data and AI to tune and adapt control loops on an ongoing basis. PiControl Solutions addresses both with PITOPS and SUPERTUNE.
In a competitive industrial landscape, the cost of leaving PID loops, APC strategies, and MPC models untouched compounds quietly: energy waste, product variability, and MPC systems that degrade until operators switch them off entirely. Process control optimization closes that gap using data the plant already collects, in the time domain, without the disruptive step tests or MPC shutdowns that conventional re-tuning and re-identification projects usually require.
Every process control optimization effort touches one or both of these areas, and each maps to a specific product in PiControl's suite.
The refinement of base-layer and advanced control loops: adjusting PID settings and APC parameters to get the desired process response. PITOPS specializes in multi-objective PID tuning and PLC- or DCS-resident APC design, and can also improve MPC systems such as PACE, RMPCT, SMOC, and DMC.
Correctly tuned PID and APC strategies are the foundation every other optimization layer depends on.
Applying machine learning and AI to plant data to uncover hidden patterns and inform control decisions. SUPERTUNE uses AI-based PID auto-tuning to optimize tens or hundreds of loops simultaneously, without changing loop modes or running step tests.
Continuous, automated tuning closes the gap between periodic tuning studies and how process dynamics actually drift.
Process control optimization is a vital discipline that empowers organizations to streamline operations, reduce costs, maintain high-quality product output, and ensure system reliability.
PITOPS fine-tunes PID loops and PLC/DCS-resident APC strategies, reducing energy consumption and lowering production costs across the loops it touches.
Tightly controlled processes minimize variability, reducing defects and keeping product consistently within specification.
PITOPS minimizes waste and optimizes resource utilization, for a more sustainable operation with the same equipment.
Proactive optimization identifies and addresses potential issues before they cause equipment failures or production stoppages.
Precise control keeps processes consistently operating within predefined safety parameters and optimal conditions.
SUPERTUNE ensures swift, automated responses to shifts in demand, helping plants stay agile and competitive without adding headcount.
Extracts true process models from data collected while controllers stay in automatic, so the plant is never disturbed to be measured.
Captures dead time, nonlinearity, and multivariable interaction that frequency-domain methods routinely lose.
PITOPS and SUPERTUNE, compatibility, step-test-free identification, and how to get started.
PITOPS and SUPERTUNE are the process control optimization engines behind PiControl's engineering practice: 10,000+ PID loops tuned across 200+ industrial facilities since 1998, on-site and remote, worldwide.
A PiControl engineer will demonstrate PITOPS and SUPERTUNE against loop and MPC dynamics relevant to your plant, and map out an optimization path for your PID loops, APC strategies, and MPC systems.