MC-APC runs a model of your line against live data, finds the optimum as it moves, and adjusts your PLC setpoints in real time to hold it there.
Machines and discrete lines
Ovens, presses and fillers run with a margin built in, because the number that matters is not measured.
Cure time, fill weight and cycle time are set for the worst case.
The worst case is not what is on the line most of the time.
Problems we hear
In the words plants use when they search.
- Paint shop oven energy
- Paint booth energy consumption
- Powder coating oven gas
- Filling weight giveaway
- Overfilling loss
- Checkweigher rejects
- Battery formation energy
- Lead acid curing chamber
- Electrode drying energy
- Oee improvement
- Machine downtime reduction
- Machine monitoring system
Engineering proposal. Begins with a free check.
What nobody measures.
Core temperature of the part
Paint and curing ovens run long, because nobody knows when the part is actually done.
Fill weight as it drifts
Every overfilled pack is margin handed to the customer, one gram at a time.
Wear of the tool and the die
The failure arrives mid-week, while the planned stop was on Sunday.
Each of these is worked out live from the physics of the readings your plant already has. MC-APC then holds each machine at its optimum as it moves, writing setpoints back to your PLC within limits you set.
The nearest proof is the machines section of Plant Ledger: MC-APC, IIoT that closes the loop.
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.
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