Find and compare the best Advanced Process Control (APC) systems in 2024
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Use the comparison tool below to compare the top Advanced Process Control (APC) systems on the market. You can filter results by user reviews, pricing, features, platform, region, support options, integrations, and more.
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Epicor Connected Process Control
Epicor Software
3 RatingsEpicor Connected Process Control provides a simple-to-use software solution that allows you to configure digital work instructions and enforce process control. It also ensures that operations are error-proof. Connect IoT devices to collect 100% time studies and process data, images and images at the task level. Real-time visibility and quality control on a new level! eFlex can handle any number of product variations or thousands of parts, whether you are a component-based or model-based manufacturer. Work instructions can be linked to Bill of Materials, ensuring that products are built correctly every time, even if changes are made during the process. Work instructions that are part a system that is advanced will automatically react to model and component variations and only display the right work instructions for what's currently being built at station. -
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Model Predictive Control Toolbox
MathWorks
$1,180 per yearModel Predictive control Toolbox™, which includes functions, an app, Simulink®, blocks, and references for the development of model predictive control (MPC), provides functions, an application, and Simulink®, blocks. The toolbox supports the creation of explicit, explicit, adaptive, gain-scheduled, and adaptive MPC for linear problems. Nonlinear problems can be solved by single- or multi-stage nonlinear MPC. The toolbox includes deployable optimization solvers, as well as the ability to create a custom solver. Closed-loop simulations can be used to evaluate controller performance in Simulink and MATLAB®. You can also use the MISRA C(r-)- and ISO 26262-compliant examples and blocks to automate driving. These blocks and examples are compatible with lane keep, path planning, following and adaptive cruise control applications. Design adaptive, gain-scheduled, or implicit MPC controllers that solve quadratic programming (QP). From an implicit design, generate an explicit MPC controller. For mixed-integer QP problems, use a discrete control set MPC. -
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MPCPy
MPCPy
FreeMPCPy is a Python package which allows you to test and implement occupant-integrated models predictive control (MPC), for building systems. The package is focused on the use data-driven, simplified statistical or physical models to predict building performance and optimize control. Four modules provide object classes that allow you to import data, interact and validate models and control input. MPCPy is an integration platform. However, it relies upon third-party, free, open-source software packages to implement models, simulates, parameter estimation algorithms, optimization solvers, and other related tasks. This includes Python packages that can be used for data manipulation and scripting, as well as more advanced software packages for specific purposes. Modelica is the language specification that is used for optimization and modeling of physical systems. -
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COLUMBO
PiControl Solutions
Closed-loop universal multivariable optimizer for Model Predictive Control's (MPC), performance and quality improvements. You can use Excel files from Aspen Tech or Honeywell RMPCT (Robust Model Predictive Control Technology), or Predict Pro (Emerson) to create and improve the correct models for each MV-CV pair. This new optimization technology is not dependent on step tests, as Honeywell and Aspen tech require. It works in the time domain, is compact and practical, and is easy to use. Model Predictive Controls can have dozens or hundreds of dynamic models. One or more of these models could be wrong. Bad (wrong), Model Predictive Control dynamic models produce a bias between the predicted signal (model prediction error), and the measured signal from the sensor. COLUMBO can help you improve Model Predictive Control models (MPC) with either closed-loop or open-loop data. -
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INCA MPC
Inca Tools
Advanced Process Control (APC), a cost-effective method to optimize your plant's performance without having to change the hardware, is very cost-effective. APC applications stabilize the operation and optimize production and/or energy use. An important side effect is a better understanding of your production process. Advanced process control (APC), refers to a wide range of technologies and techniques that interact with the base process control systems (built with PID controls). APC technologies include e.g. LQR and LQC, H_infinity, neural, fuzzy, and Model-Based Predictive Controller (MPC) are some examples of APC technologies. An APC application optimizes every minute of your plant, 24 hours a day, 7 days a week. MPC is the most widely used APC technology in the industry. Model Predictive Control software uses a model to predict the plant's behavior in the future. It can usually be done in a matter of minutes or even hours. -
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PlantPAx
Rockwell Automation
Produces like you are skilled at navigating the complexities of staying competitive. This is true across a range of industries, including pharmaceuticals, consumer packaged goods, food and beverage, mining, chemical, and chemical. It is crucial to keep up with technological advances in order to continue your digital transformation journey. Process system users, from the control room to board rooms, face the constant challenges of balancing productivity with budget and resource constraints. They also have to address evolving operational risks. PlantPAx distributed control systems (DCS) can help you meet these challenges and deliver real productivity gains across all areas of your plant. The system features positively impact the plant's lifecycle by ensuring that your plant-wide, scalable systems increase productivity, profitability, and reduce overall risk for operations. -
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Emerson DeltaV
Emerson
DeltaV S-series Electronic Marshalling (CHARMs) allows you to land field cabling anywhere you want, regardless if you use any signal type or control strategy. The DeltaV™, Distributed Control System (DCS), is an automation system that simplifies operations and lowers project risks. The state-of the-art range of products and services improves plant performance and is easy to maintain and operate. The DeltaV DCS scales easily to meet your requirements, without adding complexity. The DeltaV system integrates with other systems, such as batch, advanced control, change management and engineering tools. -
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Pavilion8
Rockwell Automation
Complex industrial processes make it difficult to be market-driven and profitable. Manufacturers need to adjust their production methods to offer a wider range of products with higher quality and shorter production runs. They must produce more, run more efficiently, and improve product quality within the limitations of their equipment. They must ensure maximum uptime, efficient transitions and less waste. Manufacturers are also being asked to reduce their environmental impact and comply with regulated emission limits. Rockwell Automation Pavilion8r Model Predictive Control technology (MPC) is an intelligence layer that sits on top of automation systems and continuously drives the plant to achieve multiple business goals, including cost reductions, decreased emissions, and production growth--all in real-time. -
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Aspen DMC3
Aspen Technology
Deep learning combined with linear and nonlinear variables allows for more accurate and long-lasting APC models that cover a wider range of operations. Rapid controller deployment, continuous model improvements and simplified workflows enable engineers to improve ROI. Automate model building with AI. Controller tuning is simplified with step-by–step wizards that allow you to specify linear or nonlinear optimization goals. Increase controller uptime with real-time cloud KPIs that can be accessed, visualized and analysed. Energy and chemical companies must operate with greater agility in today's global economy to meet market demand and maximize their margins. Aspen DMC3 is a next generation digital technology that helps companies maintain a 2-5% increase in throughput, a 3-fold increase in yield, and a 10% reduction in energy use. Learn more about next-generation advanced control technology. -
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Cybernetica CENIT
Cybernetica
Cybernetica offers Nonlinear Model Predictive Controller (NMPC) based upon mechanistic models. Cybernetica CENIT is a flexible software product that can address any industrial problem with optimal solutions. Multivariable optimal control, predictive control, intelligent feed forward, optimal constraint handling. Adaptive control via state and parameter estimation and feedback from indirect measurements through a process model. Nonlinear models can be used over larger operating ranges. Control of nonlinear processes can be improved. There is less need to perform step-response tests and there are better state and parameter estimates. Control of batch and semibatch processes, control over nonlinear processes that operate under varying conditions. Continuous processes require optimal grade transition. Safe control of exothermal process and control of unmeasured variables such as conversion rates, product quality, and other variables. Reduced energy consumption and carbon footprint -
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AVEVA APC
AVEVA
AVEVA APC is a model predictive advanced control system that improves process economics. Manufacturers are facing increasing overhead costs and reduced capital budgets in today's economic environment. They also face rising manufacturing and energy prices and fierce global competition. Comprehensive Advanced Process Control by AVEVA helps you solve complex manufacturing problems with state-of the-art automated control solutions that can extract maximum value out of your processes. It can increase production yield, quality, and reduce energy consumption. It can optimize manufacturing operations and provide the performance improvements that you need to improve your bottom-line. AVEVA APC is a comprehensive, predictive, advanced process control software that increases process profitability by improving quality, increasing throughput and reducing energy consumption. It utilizes state-of the-art technology to create automatic control systems capable of unlocking process potential. -
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System 800xA is more than a DCS (Distributed Controller System), it's also an Electrical control system, a Safety system, a collaboration enabler, and has the ability to improve engineering efficiency, operator performance and asset utilization. ABB Ability System 800xA, which has an integrated electrical control system, allows you to control the entire electrical system, including high-voltage switchgear and low-voltage motor controls. ABB Ability System 800xA can be used in conjunction with 800xA DCS. Connect to intelligent devices and reduce hardwired cabling for switchgear, regardless of the protocol. Digital communication is more reliable and can be used to improve the information flow between devices.
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Apromon
PiControl Solutions
Apromon is an online software tool that monitors the PID loop control performance of primary or advanced process control (APC) loops. Apromon can evaluate single loops, cascades, Advanced Process Control (APC), loops, and signals that have PV but no controller. Apromon can automatically convert flow controllers and temperature controllers into a single "grade", just like a professor giving a student a grade on a test or examination. 100 is the best performance, while 0 is the worst. It runs automatically every set period, so performance is always being calculated. It runs all the time and does not skip any period like competitor products. -
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Pitops
PiControl Solutions
Pitops is the only software product to perform closed-loop system ID with PID controllers in Auto mode and secondary PID controllers within a Cascade mode. This allows Pitops to identify the PID controllers without the need to break the cascade chains or conduct additional, time-consuming and intrusive step tests. Pitops is the only competitor that can perform successful transfer function identification with data from PID controllers in Cascade modes (no other tool does this). Pitops can perform transfer function identification in the time domain, whereas other tools use the more complex Laplace (S), or Discrete(Z) domains. Pitops can handle multiple inputs simultaneously and identify multiple transfer function simultaneously. Pitops can identify multiple inputs in closed-loop transfer functions system identification in time domain using a breakthrough algorithm that Pitops has developed. This algorithm is far more powerful than the older methods like ARX/ARMA/Box or Jenkins, which are used in competitors tools.
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Overview of Advanced Process Control (APC) Systems
Advanced Process Control (APC) systems are computerized control systems used to manage and optimize the performance of industrial processes. They are capable of controlling multiple variables at once, such as temperature, pressure, flow rates and product quality. These systems combine advanced mathematical algorithms and sophisticated hardware components to provide a comprehensive solution for complex process control challenges.
APC systems allow industrial facilities to greatly reduce their energy, resource and material consumption while increasing output levels by better managing and controlling all aspects of the production process. By using this type of system, an operation can minimize its waste and increase its profits through improved efficiency. In addition, APC systems can help prevent costly shutdowns due to safety or process control issues.
At the core of an APC system is a controller that constantly monitors and adjusts process variables according to defined parameters (or setpoints). Depending on the complexity of the task at hand, different types of controllers may be employed including PID controllers (Proportional Integral Derivative), fuzzy logic controllers or model predictive controllers (MPCs). The controller works in harmony with other components such as sensors and networked computers that feed data into it in order to create a feedback loop which helps maintain optimal performance levels in real-time.
The main benefit provided by an APC system over traditional analog or digital control methods is the ability to quickly detect small changes in performance conditions even when many variables are in play at once. This allows operations personnel to take corrective action much faster than they could with manual processes. In addition, since these systems utilize advanced analytics they can suggest alternative strategies for increasing efficiency which may not have been considered otherwise.
Overall, APC systems offer a wide range of benefits including increased efficiency, decreased maintenance costs, less waste production and higher profitability for manufacturing operations - making them well worth considering for any organization looking to improve their operational productivity.
Why Use Advanced Process Control (APC) Systems?
- Cost Savings: Advanced Process Control (APC) systems can provide cost savings for organizations by using sophisticated control algorithms to optimize material and energy usage and reduce operational costs.
- Increased Efficiency: APC systems are designed to improve plant efficiency by monitoring process variables such as pressure, temperature, flow, level, and composition to make automated adjustments that will increase yield or reduce fuel consumption.
- Improved Quality: By providing a better understanding of the process, APC systems help operators identify problems before they become an issue and address them quickly so quality is maintained.
- Better Operational Performance: The predictive capabilities of APC systems allow it to anticipate changes in external conditions such as raw material availability or a sudden influx of power supply; these proactive steps can be taken before they occur helping the organization avoid downtime due to unexpected events or fluctuations in resources prices that may affect overall operation performance.
- Improved Safety: With the ability to continuously monitor safety-related parameters such as temperature, pressure and chemical levels in hazardous areas, APC processes can help prevent potential accidents from occurring at production sites leading to improved worker safety levels across operations personnel working within those environments.
Why Are Advanced Process Control (APC) Systems Important?
Advanced process control (APC) systems are becoming increasingly important as businesses strive to improve their production processes. APC systems provide a way for companies to optimize their processes without manual intervention, allowing operations to run more smoothly and cost-effectively.
The most significant benefit of using APC systems is that they allow companies to increase productivity while reducing costs. By automating certain parts of the production process, APC systems can help reduce human errors, eliminate guesswork, and make it easier for operators to monitor overall performance levels. This means that production lines can become more efficient and accurate, leading to higher quality output with fewer resources being expended.
Another key benefit of utilizing APC technologies is improved safety standards in industrial settings. Automation enhances safety by removing the need for workers to manually handle hazardous materials or operate dangerous machinery. This also helps lower accident rates on factory floors where increased efficiency measures might require faster speeds or longer hours from employees. Workers will be able to stay healthier and safer when automated controls have been implemented correctly.
Finally, modern APC solutions are integrated with big data analytics tools which allows manufacturers to quickly adjust their production processes based on customer demand cycles or environmental conditions like temperature shifts or changes in humidity levels across different geographical locations. This helps minimize waste resulting from overproducing or underproducing items; thereby saving money in both raw material costs and labor expenses as well as better meeting customer demands in terms of time frames associated with delivery deadlines or order fulfillment expectations.
In summary, advanced process control (APC) systems offer an invaluable tool for improving productivity while maintaining high standards of safety across manufacturing sites around the world; all this at reduced costs compared with traditional manual approaches used before implementation took place.
Features Provided by Advanced Process Control (APC) Systems
- Multivariable Control: APC systems can simultaneously control multiple process variables, such as temperature and pressure, to ensure optimal performance in terms of product quality, throughput, cost and energy efficiency.
- Model-Predictive Control (MPC): MPC uses advanced mathematical models and algorithms to predict future outcomes based on current plant conditions. This helps optimize process operation by predicting the most beneficial adjustment for future changes in process assets.
- Optimization: APC systems provide optimization capabilities that enable efficient control of a range of operations from small unit operations up to complex chemical processes or entire production lines. Optimization algorithms are used to identify the best set points for different process operating parameters in order to minimize costs while meeting all required safety constraints.
- Integrated Data Analysis: Advanced process control systems utilize integrated data analysis techniques such as root cause analysis or statistical process control (SPC) charts with high speed sampling which allows rapid detection of abnormalities which might be difficult to detect through traditional manual methods alone.
- Automation: With the help of an APC system, it is possible to automate complex processes with minimal human intervention while maintaining high levels of consistency and accuracy across different equipment types and production batches within a plant or across locations distributed geographically around the world leading to increased levels of efficiency at scale up manufacturing processes.
What Types of Users Can Benefit From Advanced Process Control (APC) Systems?
- Plant Operators: Plant operators can benefit from APC systems by having better control over their processes and being able to respond quickly to changes. This helps them optimize production, reduce costs, and improve safety.
- Process Engineers: Process engineers can use APC systems to monitor process conditions in real-time, identify problems quickly and implement corrections before they become big issues.
- Maintenance Teams: Advanced process control systems help maintenance teams get a better overview of their entire system by providing them with detailed data on all the different components that make up the plant equipment. This allows them to manage maintenance activities more efficiently, resulting in fewer unplanned shutdowns.
- IT Professionals: Advanced process control systems provide IT professionals with a layer of sophisticated algorithms and automation tools that help reduce downtime and increase efficiency throughout the production chain.
- Quality Assurance Specialists: Quality assurance specialists can also see benefits from advanced process control because it enables them to maintain consistent product quality by identifying potential problems early on and taking corrective action when needed.
- Managers & Executives: Advanced process control systems are great for managers and executives since they provide real-time visibility into operations across departments, giving leaders greater oversight into how their organization is performing as a whole. They can then use this information to make decisions about where resources should be allocated or what strategies should be implemented for future success.
How Much Do Advanced Process Control (APC) Systems Cost?
The cost of an advanced process control (APC) system can vary significantly depending on the complexity and size of the project. Generally, a complete APC system can range from tens of thousands to hundreds of thousands of dollars for smaller projects and up to millions for larger projects. The costs depend on the number of process variables to be controlled, the number and type of controllers used, and other factors such as hardware, software licenses, engineering services, installation services, maintenance costs, etc.
For smaller projects with few process variables and simpler control requirements, basic controller hardware might cost around $50K -$100K. Once engineering services fees are added ($20K-$60K) and additional hardware/software license fees ($8k-$20K), you might end up in an overall cost range between $80k-200k.
For more complex or larger systems with many process variables to optimize simultaneously, prices may start at around $250k and go up exponentially depending on complexity. In addition to the greater number of instrumentation points that would need to be monitored/controlled (i.e., more instruments/controllers needed); extra expenses associated with a larger system include extra wiring costs ($10-15k), extra software licensing fees (upwards from $30K+), programming & commissioning labor (~$50-100K), additional operational training (~$5-10k). A large multi variable APC system could potentially exceed costs in excess several million dollars for materials alone when all is said & done before taking into account any additional soft cost considerations resulting like labor hours or extended service packages.
Risks To Consider With Advanced Process Control (APC) Systems
The risks associated with Advanced Process Control (APC) systems include:
- Poor implementation of APC can lead to severe process upsets and upset product quality.
- The infrastructure required to run an APC system such as cables and networks may introduce reliability and security issues.
- Lack of personnel trained in APC or understanding the algorithms used to optimize the system can cause errors and costly downtime.
- If a problem occurs, the detection could be missed due to the complexity of the processes being monitored by the APC system.
- Unintended consequences from adjustments made to control parameters occur due to poor tuning or lack of understanding about how it interacts with other parts of the plant.
- There is a risk that advanced process control systems might create excessive confusion for operators during certain scenarios, leading them identify wrong alarms or interpret information incorrectly.
What Software Do Advanced Process Control (APC) Systems Integrate With?
Advanced Process Control (APC) systems can integrate with a variety of software programs for data collection, analysis and presentation. Some specific examples include industrial process automation software, statistical process control (SPC) software, Manufacturing Execution System (MES) software and Human Machine Interface (HMI). These systems enable users to automatically monitor production processes in order to keep them running at the most efficient levels. Data collected by APC systems is analyzed using SPC software which helps to identify patterns or issues related to a process. This information can then be used by MES software to optimize production and ensure that all processes are running properly. Finally, HMI software provides a graphical interface for visually monitoring and controlling machines remotely, as well as displaying any errors that may occur. All of these types of software work together with an APC system to provide visibility into the performance of manufacturing operations so that any potential problems can be quickly addressed before they become major issues.
Questions To Ask Related To Advanced Process Control (APC) Systems
- How will the APC system monitor and control all stages of the process?
- What specific improvements in efficiency, production rate or quality can be expected with APC installed?
- Are there any financial savings or incentives associated with implementing an APC system?
- Is the technology suitable for different processes, like batch or continuous operation?
- Is the proposed solution scalable and easily extendable to accommodate future grows and needs?
- Are special training and personnel requirements necessary for successful implementation of the technology?
- What is the maintenance schedule for maintaining peak performance over time?
- What are the terms of warranty and support included with installation/upgrade of APC system?