Use Case Artificial Intelligence: Process Optimization of Distillation Process
HAI experts have crafted a robust Manufacturing Insights tool designed for advanced statistical process monitoring and predictive modeling. The AI…
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High Expectations, Demanding Operations
Whether batch or continuous, chemical processes are complex and demanding:
- High precision: Molecular composition must be exact; small deviations can affect product performance or safety
- Safety and environmental compliance: Handling toxic, flammable, or corrosive substances requires strict regulation
- Controlling batch duration and ensuring consistent quality
Yet you’re expected to maximize output, minimize downtime, and run lean — while minimizing environmental impact and water and energy consumption.
How HAI helps
The HAI software is designed for automatic collection of measurements on raw materials, process conditions, operator input, and product characteristics. It detects anomalies in real time while analyzing historical trends and cost insights — giving you full control in real-time monitoring as well as process optimization.
Read more about HAI in the Chemical Industry
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“Our focus is on producing higher volumes at lower cost, whilst maintaining our high level of flexible and adequate customer fulfilment. If we can achieve this by simply working smarter, that’s the way to go”
Operations Director
Data-Driven Process Control
- Full visibility
from raw materials, through processing and endproduct quality and performance. - Real-time monitoring
continuous monitoring of process instrumentation along with product characteristics, chemical reaction mechanisms vs. process models, batch duration, yield, etc. - Consistent quality
ensure output meets specs every time. - Total traceability
link every batch to its source and process history. - Smarter sustainability
reduce waste, energy & water consumption, and resource use.
HAI: From Data to Decisions
HAI brings clarity to complexity. The software collects and analyzes all critical process and quality data, delivering:
- Real-time dashboards, trends, and early warnings for operators (Golden Batch monitoring,trending and advanced data analysis)
- AI-powered insights, reports, and deep analytics for production and quality teams (predictions and process setting adjustments).
- Faster, more consistent batch release
- Continuous improvement through troubleshooting and optimization
With HAI, you gain full control of your process—turning data into action and performance into profit.
“I need reliable plant performance reports, which give me a clear understanding of what happens in production. We used to make decisions largely based on experience and intuition. The real-time HAI dashboards and reports help us to make more data-driven decisions.”
Quote from a Plant manager
Your benefits
- One central database
instant access to all quality and process data, inclusding measurement devices and weighing scales; no more searching through SCADA, ERP, Excel, or lab systems. - Real-time dashboards
instantly detect deviations and ensure compliance. - Fewer rejected batches
improve yield and reduce waste. - Consistent product quality
every batch, every time.
- Optimized process settings
enable faster, more stable production. - Maximum performance
increase uptime, speed, and OEE.
- Smarter operations
reduce energy and water use while optimizing Cleaning and Maintenance. - Deep process insight
track every step: raw materials quality, processing conditions, end-product quality and packing.
What you’ll have
- Centralize all production and quality data in one real-time operational datastore
- HAI integrates seamlessly with PLC/SCADA, Historians, ERP systems (e.g. SAP, Infor, Microsoft, Oracle), LIMS, and in-line inspection equipment such as weighing scales, vision systems, metal detectors etc.
- Operator quality control checks
- Start-up and cleaning checklists
- Inspections & Product Quality tests (e.g. visual inspections)
Replace Excel-based lab and production logs with intuitive data-entry screens directly in the HAI Platform.
- Interactive real-time logsheets combining production-, lab-, equipment-, and operator-data
- Compliance dashboards for process parameters, energy/water consumption, and quality standards
- Real-time trending, SPC, and correlation tools for early warnings and root-cause analysis
- Real-time KPIs (e.g., OEE, First Time Right), yield, mass balance, runtimes, downtime, cost per batch
- Predictive analytics on end-product quality
- Comprehensive tracking & tracing, exception reporting, and cost validation tools
Simply available in the Cloud …. No capital investment …. Subscription-based.
Intuitive, yet powerful
- Fast implementation – up and running quickly across lines and sites.
- Easy to manage – intuitive interface, no complex IT skills required.
- User-driven – after brief training, users can fully operate and adapt the system on their own.
- Custom dashboards – build logsheets and views tailored to any role or workstation.
- Context-rich insights – data from multiple sources is linked to real production conditions, making insights instantly meaningful and actionable.
