Thermo-Cognitive Advanced Process Control (TC-APC) models, simulates and optimizes your process in real time to improve yield, conversion and throughput, and reduce energy use, with a quick payback.
Any process, any industry
Every process has a boiling point.
Some number that tells you something is happening, and not what.
Find the one your plant cannot see, and there is money behind it.
The test
Three questions decide whether there is money in your process.
01
Does a number nobody measures decide the money?
Composition, conversion, moisture, calorific value, core temperature: something the plant only learns about afterward.
02
Is it run on a fixed recipe?
A setpoint, a timer or a rule of thumb, chosen once and kept because it is safe.
03
Does the constraint move?
Feed, fuel, weather, wear and raw material all change. The recipe does not.
If all three are true, there is a margin, and the only question is its size. The free check answers that, including the answer that it is not worth pursuing.
Seven families of plants
Find yours.
- Chemicals, pharma and agrochemicals The batch is judged by the laboratory, hours after it could still have been saved.
- Sugar, ethanol and fermentation The pan and the fermenter both run on numbers nobody measures.
- Food, dairy and edible oil Moisture, oil and solvent leave with the product, and the plant finds out at the laboratory.
- Kilns, furnaces and metals The fuel bill is set by a temperature nobody can see, inside the tile, the billet or the charge.
- Polymers, rubber, textiles and paper Viscosity, moisture and shade drift inside the run, and the rejects arrive at the end.
- Utilities, water and power Every plant pays for steam, air, cooling and water. Few know what each tonne of product costs in them.
- Machines and discrete lines Ovens, presses and fillers run with a margin built in, because the number that matters is not measured.
The ten application pages go deeper on the processes we know best. Our deployed reference is soda ash carbonation, and the track record page says exactly what has run and what is proposed.
What we commit to
The same eight commitments, on every project.
No gain, no project
If the check finds nothing worth doing, we say so and stop there.
Savings on your own meters
Before and after, on your instruments, so the result is yours to check.
Shadow mode first
It writes setpoints only after you have watched it be right.
Interlocks untouched
Trips, interlocks and the safety system stay under their own logic.
Runs inside your plant
On its own industrial system and your network, working when the internet is not.
Uses existing instruments
It reads what your DCS, PLC or SLC already measures, and says so where one instrument would close a gap.
Physics first, then AI
A model of the process's own physics, with learning only for what physics cannot know.
Published in Chemical Weekly
The approach, set out as a Special Report in October 2025.
The mark
Find the optimum. Hold it while it moves.
The curve is a yield or selectivity response. The amber point is the optimum, and the dashed drop is where it sits on the operating axis.
The second half of the line is the part that matters. Finding an optimum is a study, and studies end up in drawers. Holding one while the feed, the fouling, the weather and the wear keep moving it is a control problem, and that is the work.
Start with your log sheets
Send one month of log sheets from one area
Photographs are fine. We will show you what the area is losing, which meters disagree with the physics, and what that is worth, including the answer that there is nothing worth pursuing. No charge, and no commitment either way.
Or start with three months of data
If you already keep a historian
Send three months of operating data from one unit, with the laboratory results beside it. The same exercise, done faster, with the same honest answer at the end. How both work.
projects@yielddynamics.in Talk to IIT Bombay engineers Call +91 94230 07004Monday to Saturday, 9:00 to 19:00 IST