INSUS analyzes process, production, quality and energy data to recommend operating parameters as equipment, feedstock and conditions change, helping teams balance efficiency with quality and throughput targets. Process teams keep the decision.
01
Parameters drift as equipment, feedstock and conditions change.
02
Static setpoints can waste energy or reduce performance.
03
Recommendations stay within validated process limits.
The problem
Pharmaceutical manufacturing is energy-intensive and depends on precise conditions across HVAC, drying, mixing, compression and other operations. Parameters can move away from optimal ranges as equipment fouls, feedstock varies, catalyst ages or production requirements change. Fixed setpoints and slow manual adjustments can mean higher energy use, more variability, lower throughput or shifts in critical quality attributes before anyone responds.
The shift
Operators and process engineers stay responsible for every setpoint change within validated limits. What changes is whether recommended parameters reflect the current process state, not only the last campaign's defaults.
Today
With INSUS
How it works
This fits OptiStudio as process and energy decision support beside existing DCS and quality systems. Access is read-only. It does not automatically change validated process parameters.
Connect
Connect read-only to DCS, PLCs, SCADA, historians, LIMS, MES, process instrumentation and energy or utility data already available to the plant.
Understand
Analyze relationships between process variables, energy behavior and quality or production outcomes for the specific unit or line.
Detect
Identify deviations from expected or optimal operating behavior and patterns that may affect quality, yield or energy performance.
Advise
Recommend parameter combinations expected to improve energy efficiency, yield or throughput while staying within validated quality and safety constraints.
Verify
Compare predicted and actual energy, quality and production outcomes so the model can be validated and refined for the specific process and product.
Getting started
For pharmaceutical manufacturers that already collect process, quality and energy data. Delivered through OptiStudio as process decision support. Expert Services can help with data assessment and validation. Advisory and read-only. Implementation must fit applicable quality and validation requirements.
Related for pharma
Process parameter optimization sits beside batch yield prediction and contamination risk prediction on the same pharmaceutical operation.
Process parameters drift as equipment and conditions change. This use case flags drift and recommends operating parameters for process-team review within validated constraints.
Energy-intensive areas such as HVAC, drying, mixing and compression are common starting points. Suitability depends on available data, validated limits and measurable objectives for the unit.
DCS, SCADA, historian, LIMS, MES, process instrumentation and energy data. No new sensors when those systems already exist.
No. Initial deployment is advisory. Qualified operators and engineers review every recommendation, especially where regulatory and validation requirements apply.
Yes. Recommendations can consider multiple objectives, but energy reduction is not treated as the only goal. Validated quality and process constraints stay in force.
Through OptiStudio as process and energy decision support. Expert Services can support data assessment, integration and validation with your process team.
Performance depends on reliable process and quality history. Recommendations are process-specific. The system does not guarantee energy savings, yield gains or replace change-control and validation procedures.
Pharma · Process parameter optimization
Use your own process and energy data to understand changing conditions and give teams a data-informed basis for parameter decisions within validated operating constraints.
