Advanced Industrial Process Control Systems

Detailed overview of innovation with sample startups and prominent university research

What it is

Advanced process control (APC) systems are sophisticated control strategies that go beyond traditional control methods to optimize industrial processes. These systems utilize advanced algorithms and models to continuously monitor and adjust process parameters, maximizing efficiency, improving product quality, and reducing waste.

Impact on climate action

Advanced Process Control Systems in Energy-Efficient Industrial Equipment optimize energy usage and production processes. By regulating equipment operations in real-time, these innovations minimize energy waste, reduce carbon emissions, and enhance industrial efficiency, contributing to climate action by lowering energy consumption and promoting sustainable manufacturing practices.


  • Model Predictive Control (MPC): MPC uses a dynamic process model to predict future process behavior and calculate optimal control actions to achieve desired outcomes.
  • Adaptive Control: Adaptive control systems adjust their control parameters based on real-time process data, adapting to changing conditions and disturbances.
  • Multivariable Control: Multivariable control techniques consider the interactions between multiple process variables, allowing for more precise and coordinated control.
  • Artificial Intelligence (AI) and Machine Learning (ML): AI and ML algorithms can be used to analyze process data, identify patterns and anomalies, and develop predictive models for process optimization.
  • Real-time Optimization (RTO): RTO systems continuously optimize process parameters based on economic objectives, such as maximizing profit or minimizing costs.

TRL : 7-8

Prominent Innovation themes

  • AI-Powered APC: Advancements in AI and ML are enabling the development of more sophisticated and adaptive APC systems that can learn from process data and optimize performance in real-time.
  • Cloud-Based APC Solutions: Cloud-based APC platforms are making it easier to deploy and manage APC systems, reducing costs and increasing accessibility for businesses.
  • Hybrid APC Strategies: Combining different APC techniques, such as MPC and adaptive control, can provide more robust and flexible control solutions.
  • Integration with Digital Twins: APC systems are being integrated with digital twins to enable real-time process optimization and closed-loop control.

Other Innovation Subthemes

  • Enhanced Energy Optimization Techniques
  • AI-Driven Predictive Maintenance
  • Real-time Adaptive Control Strategies
  • Integration with IoT for Enhanced Monitoring
  • Cloud-Based Process Optimization Platforms
  • Next-Generation Control Algorithms
  • Digital Twin Integration for Process Simulation
  • Advanced Data Analytics for Process Insights
  • Industrial AI for Enhanced Decision Making
  • Optimization of Resource Utilization
  • Autonomous Process Control Systems
  • Energy-Efficient Heating and Cooling Solutions
  • Advanced Control Systems for Renewable Energy
  • Smart Sensors for Real-time Process Monitoring

Sample Global Startups and Companies

  1. Arundo Analytics:
    • Technology Enhancement: Arundo Analytics provides industrial analytics and machine learning solutions for advanced process control in complex industrial environments. Their platform collects, analyzes, and visualizes data from industrial assets and processes, enabling real-time insights and decision-making. Arundo’s solutions utilize AI and machine learning algorithms to optimize process efficiency, reliability, and safety.
    • Uniqueness of the Startup: Arundo Analytics stands out for its focus on industrial data analytics and its expertise in delivering actionable insights for process optimization. Their platform is designed to address the unique challenges of industrial operations, such as variability, complexity, and regulatory compliance, helping customers unlock value from their data and improve operational performance.
    • End-User Segments Addressing: Arundo Analytics serves industries such as oil and gas, manufacturing, utilities, and maritime, where advanced process control is critical for optimizing production, reducing downtime, and ensuring safety and compliance. Their solutions are deployed in diverse industrial environments, including refineries, chemical plants, power plants, and offshore assets.
  2. Falkonry:
    • Technology Enhancement: Falkonry offers predictive analytics solutions for industrial process monitoring and optimization. Their platform utilizes machine learning techniques such as pattern recognition and anomaly detection to identify operational patterns, predict equipment failures, and optimize process performance. Falkonry’s solutions are designed to be easily deployed and integrated with existing industrial systems.
    • Uniqueness of the Startup: Falkonry stands out for its focus on predictive analytics and its ability to deliver actionable insights without requiring extensive data science expertise. Their platform empowers industrial operators and engineers to leverage machine learning for process improvement, asset management, and predictive maintenance, enabling proactive decision-making and risk mitigation.
    • End-User Segments Addressing: Falkonry serves a wide range of industries, including manufacturing, energy, aerospace, and automotive, where predictive maintenance and process optimization are critical for operational efficiency and asset reliability. Their solutions are deployed in industrial plants, production facilities, and manufacturing lines, helping customers enhance productivity and reduce costs.
  3. Canvass Analytics:
    • Technology Enhancement: Canvass Analytics provides AI-powered predictive analytics solutions for industrial process optimization and automation. Their platform leverages machine learning algorithms to analyze sensor data, identify patterns, and optimize process parameters in real time. Canvass Analytics enables continuous improvement in production efficiency, quality, and resource utilization.
    • Uniqueness of the Startup: Canvass Analytics stands out for its focus on industrial AI and its ability to deliver scalable and actionable insights for process optimization. Their platform is designed to integrate seamlessly with existing industrial systems, enabling rapid deployment and ROI realization. Canvass Analytics empowers industrial organizations to unlock the full potential of their data and drive operational excellence.
    • End-User Segments Addressing: Canvass Analytics serves industries such as manufacturing, energy, chemicals, and utilities, where data-driven decision-making is essential for maintaining competitiveness and sustainability. Their solutions are deployed in diverse industrial settings, including production plants, power generation facilities, and distribution networks, helping customers improve asset performance and operational efficiency.

Sample Research At Top-Tier Universities

  1. Massachusetts Institute of Technology (MIT):
    • Research Focus: MIT is a leader in research on Advanced Process Control Systems, focusing on developing cutting-edge control algorithms, optimization techniques, and predictive analytics for improving the energy efficiency, productivity, and sustainability of industrial processes and equipment.
    • Uniqueness: Their research involves the integration of advanced sensors, actuators, and data analytics platforms to enable real-time monitoring, analysis, and control of complex manufacturing processes. They also develop model-based control strategies, adaptive learning algorithms, and distributed control architectures to optimize energy consumption, minimize waste, and enhance product quality in diverse industrial sectors.
    • End-use Applications: The outcomes of their work have applications in chemical processing, manufacturing, power generation, and building automation. By implementing advanced process control systems, MIT’s research enables industrial facilities to achieve significant energy savings, reduce emissions, and enhance competitiveness in a rapidly evolving global market.
  2. Stanford University:
    • Research Focus: Stanford University conducts innovative research on Advanced Process Control Systems, leveraging its expertise in control theory, machine learning, and cyber-physical systems to develop intelligent control solutions for energy-efficient industrial equipment and processes.
    • Uniqueness: Their research encompasses the development of data-driven control algorithms, distributed control architectures, and adaptive optimization techniques tailored to the unique characteristics and operational constraints of industrial systems. They also explore the integration of digital twins, virtual sensors, and reinforcement learning algorithms to enable autonomous and adaptive control of energy-intensive processes.
    • End-use Applications: The outcomes of their work find applications in semiconductor manufacturing, oil and gas refining, food processing, and renewable energy production. By advancing process control technologies, Stanford’s research helps industries optimize resource utilization, reduce operating costs, and minimize environmental impacts, contributing to a more sustainable and resilient industrial ecosystem.
  3. University of California, Berkeley:
    • Research Focus: UC Berkeley is engaged in cutting-edge research on Advanced Process Control Systems, leveraging its expertise in control engineering, optimization theory, and cyber-physical systems to develop innovative control solutions for improving energy efficiency and sustainability in industrial operations.
    • Uniqueness: Their research involves the development of distributed control algorithms, adaptive control strategies, and fault detection techniques for enhancing the performance and reliability of industrial equipment and processes. They also explore the integration of machine learning, model predictive control, and system identification methods to address dynamic process variations and uncertainties.
    • End-use Applications: The outcomes of their work have applications in manufacturing automation, chemical processing, energy management, and smart grid integration. By deploying advanced process control systems, UC Berkeley’s research enables industries to optimize energy use, reduce greenhouse gas emissions, and achieve operational excellence in a rapidly evolving and competitive market landscape.

commercial_img Commercial Implementation

Advanced process control systems are widely implemented in various industries, including chemical processing, oil and gas, and power generation. These systems are helping businesses improve efficiency, reduce costs, and minimize environmental impact.