Continuously optimize setpoints, align SOPs with real operations, and deliver explainable decisions your teams can execute safely.
Energy-intensive plants run hundreds of interdependent variables where small changes create non-linear impact on energy, quality, and equipment health.
Complexity
Plants run on variables that interact in non-linear ways. Changing one setpoint ripples through energy use, product quality, and equipment health in ways that spreadsheets and manual analysis cannot track.
Outdated SOPs
Standard operating procedures drift from actual plant behavior over time. Engineers do not have the bandwidth to audit and update them continuously, leaving operators without reliable guidance.
Reactive tools
Most industrial software shows what happened. OptiStudio shows what to do next continuously surfacing optimized recommendations operators can act on in real time.
AI in silos
AI proof-of-concepts succeed in the lab but fail to reach the plant floor. Without operationalization, insights stay locked in models and dashboards, never influencing the shift.
Platform execution
ML Optimizer and SOP Generator keep setpoint intelligence and procedure governance in sync from model to shift floor.
ML OptimizerData Foundation
OptiStudio combines governed data, optimization intelligence, and SOP execution workflows into one production-ready operating layer.
Ingest and harmonize historian, lab, and operational data from any source into a clean, structured foundation for AI.
Combine first-principles process knowledge with machine learning to build models that are accurate, interpretable, and robust.
Simultaneously optimize energy, quality, throughput, and emissions under real plant constraints not one variable at a time.
Audit existing procedures, detect gaps from optimized operations, and generate structured SOP drafts engineers can review and approve.
Test operating strategies virtually before deploying them. Compare scenarios side-by-side with full transparency into trade-offs.
Surface optimized setpoints and guidance in operator interfaces explainable, traceable, and safe to act on every shift.
Connect recommendations to DCS and control systems for automated or semi-automated deployment of optimized setpoints.
Role-based access control, full audit logs, and traceability to meet industrial compliance and safety requirements.
5–15% energy reduction per ton, 3–10% OEE improvement, 3–8% CO₂ intensity reduction, and 6–18 month payback on targeted deployments.
5–15%
3–10% OEE improvement and 3–8% CO₂ intensity reduction on comparable energy-intensive lines.
Real project Rigid foam insulation
Constrained optimization across 44 variables and ~26,000 records reduced core density from ~1.656 to 1.628 g/cm³ while maintaining high quality pass rates.
Minimize core density across 7 plants while preserving quality
Generated optimization insights were translated into updated SOP guidance for formulation settings and operating windows at each site.
6–18 mo
Multi-site rigid foam insulation deployment with governed optimization and SOP alignment across seven plants.
Use cases
Multi-objective optimization across cement, steel, chemicals, and utilities trained on your plant's constraints, not generic APC templates.
Optimize kiln fuel consumption, clinker quality, and throughput simultaneously. Reduce specific heat consumption while maintaining product specifications across varying raw material inputs.
Balance furnace temperature profiles, energy input, and product metallurgy across complex interdependencies. Reduce reheating costs and improve yield while meeting tight dimensional tolerances.
Optimize reactors, distillation, utilities, and changeover procedures with governed setpoints that maintain safety envelopes, quality targets, and compliance.
Reduce cycle times, minimize material waste, and improve first-pass quality across production lines. Optimize machine setpoints and scheduling for maximum OEE.
Minimize energy cost across assets with variable load profiles. Align consumption with energy pricing signals and optimize across multiple energy vectors simultaneously.
Optimize generation dispatch, load balancing, and asset utilization across distributed infrastructure. Reduce fuel costs while meeting reliability and compliance requirements.
OptiStudio connects plant data, procedures, and business systems into one optimization-ready layer.
Talk to an expertOptiStudio
Multi-objective: energy, quality, throughput, emissions
Traditional APC / EMS
Single-variable or single-objective
OptiStudio
Built-in SOP audit, gap detection, and draft generation
Traditional APC / EMS
Not included
OptiStudio
Hybrid: process physics + AI
Traditional APC / EMS
Statistical or rule-based
OptiStudio
Integrated recommendations surfaced in operator workflows
Traditional APC / EMS
Separate system or dashboard
OptiStudio
Built-in what-if and scenario studio
Traditional APC / EMS
Limited or manual
OptiStudio
Native DCS/control system integration
Traditional APC / EMS
Requires custom integration
Traditional APC focuses on single-variable control loops. OptiStudio runs multi-objective optimization simultaneously across energy, quality, throughput, and emissions while also managing the SOP lifecycle and surfacing explainable recommendations operators can act on.
Yes. The SOP Alignment module audits current procedures against optimized plant behavior, detects gaps, and generates structured SOP drafts. Engineers review and approve OptiStudio surfaces the work, your team owns the outcome.
OptiStudio ingests data from historians (OSIsoft PI, AspenTech, etc.), lab systems, and operational databases. A focused rollout typically starts with 12–24 months of historical data and expands from there.
Yes. OptiStudio is built for multi-site, multi-line deployment. Models can be shared, adapted, and governed across sites while maintaining local operational context.
OptiStudio operates in read-first mode by default, with recommendations surfaced to operators before any control action. Closed-loop integration includes safety constraints and operator override at every step. Role-based access and audit logging meet industrial compliance standards.
Start with one line or utility system, demonstrate value, and scale with repeatable optimization and SOP governance workflows.
