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.
Polymers, rubber, textiles and paper
Viscosity, moisture and shade drift inside the run, and the rejects arrive at the end.
Extruders, mixers, dryers and dyeing machines hold their settings steady.
The material they are working on does not stay the same.
Problems we hear
In the words plants use when they search.
- Extruder melt temperature variation
- Extrusion output variation
- Film thickness variation
- Dyeing shade variation
- Re-dyeing reduction
- Dyeing right first time
- Paper machine steam consumption
- Paper moisture variation
- Paper moisture profile
- Mooney viscosity variation
- Banbury mixing cycle time
- Rubber compound batch variation
Engineering proposal. Begins with a free check.
What nobody measures.
Viscosity of the melt or compound
The mixer and the extruder feel it in their motors long before the laboratory does.
Moisture across the web
Paper and fabric are dried to the wettest spot, so the rest is overdried and the steam is wasted.
Dye taken up by the fiber
Right first time depends on the bath, which changes while the recipe does not.
Each of these is worked out live from the physics of the readings your plant already has. TC-APC then holds the process at the optimum as it moves, writing setpoints back to your DCS, PLC or SLC within limits you set.
The nearest proof pages are protein gelation, where a paste is read through the machine that works it, and Plant Ledger.
Optimize your extruders with TC-APC
More tonnes. Less power.
Your best shift, every shift.
Thermo-Cognitive Advanced Process Control (TC-APC): more throughput, less energy in compounding and extrusion.
The melt changes. Your setpoints don’t. With TC-APC, they do.
More good kilograms every running hour, and less energy for each one.
What TC-APC does on your extruder
- Optimizes and adjusts the extruder in real time as the melt changes, from lot to lot, hour to hour and shift to shift, and as the machine wears. Throughput goes up and energy per kilogram comes down, across your grades and on every shift. It works through your DCS, PLC or SLC, within limits you set. It runs the extruder close to its true capacity, always keeping a safety margin for sudden spikes, so it adds no trips.
- Every move is small and recorded. Your operator can switch it off at any moment.
- Runs on its own industrial system. Trips and interlocks stay untouched, and if it ever stops, the extruder simply returns to its own recipe.
Your number, worked out
₹90 lakh a year
per extruder, plus energy savings
Even 2% more on a 2,000 kg/h line running 7,500 hours is 300 tonnes a year: about ₹90 lakh at ₹30 a kg contribution.
We work out your own number free, from one month of log sheets.
The one-page flyer. Click to read it full size.The one-page flyer. Tap to open it.
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