About This Model

ProcessIQ: Industrial Process Intelligence & Predictive Quality Platform

ProcessIQ is a vendor-agnostic industrial intelligence platform for continuous manufacturing: web converting, roll-to-roll coating, extrusion, calendering, mixing, stamping, and CNC machining across all continuous process plants.

Combining machine telemetry with deterministic statistical control (Dynamic PCA + CUSUM) and schema-validated AI, ProcessIQ flags multivariate drift 15–45 minutes before scrap is produced, pinpoints root causes, and bridges the 7–21 day delay between production and offline quality labs.

Supported Machinery Across Continuous Manufacturing Plants

Machinery

Monitored Variables

Industrial Value

Slot-Die / Roll Coaters

Mass flow, lip gap (0.1 µm), web speed, temp

Flags coat weight drift & rheology shifts early

Extruders (Single/Twin)

Melt pressure, barrel temps, screw RPM, kW

Flags thermal degradation, viscosity shifts & die buildup

Calendering & Nip Rolls

Nip force (kN), web tension (N), roll temp

Prevents foil wrinkling, thickness variation & defects

Industrial Mixers

Agitator kW, shaft torque, jacket temp, flow

Monitors shear behavior, slurry rheology & batch uniformity

Dryers & Ovens

Multi-zone temps, air velocity, exhaust VOCs

Prevents thermal non-uniformity, blistering & solvent traps

Stamping Presses

Tonnage curves, cushion force, acceleration

Identifies tool wear, punch cracking & sheet defects

5-Axis CNC Machining

Spindle load, axis vibration, following error

Detects tool wear, chatter vibrations & thermal growth

17 Comprehensive Physical Sensor Families Supported

Sensor Family

Hardware & Transducers

Industrial Application & Value

1. Power & Current

Split-Core CTs, Rogowski coils, 3-phase kW

Non-invasive proxy for fluid viscosity & motor load

2. Mass & Flow

Coriolis mass flowmeters (kg/min, density)

Mass balance tracking, feed rate & phase separation

3. Displacement/Gap

Chromatic confocal, optical scales (Heidenhain)

0.1 µm lip/roll gap tracking; thermal expansion

4. Nip Force/Tension

Shear load cells, tension sensors (HBM, Kistler)

Prevents web wrinkling, transverse imbalance & tension spikes

5. Melt/Fluid Pressure

Diaphragm transducers, melt sensors (Dynisco)

Slurry/melt rheology; flags nozzle & die clogging

6. Multi-Zone Temp

Pt100 RTDs, thermocouples, IR pyrometers

Drying kinetics; prevents blistering or cracks

7. Vibration & Shock

IEPE/ICP accelerometers, 3-axis MEMS (PCB, ifm)

Bearing wear, roll chatter & mechanical unbalance

8. In-Line Metrology

Laser triangulation, beta/X-ray scanners (g/m²)

Virtual metrology ground truth & calibration

9. Ultrasound/Acoustic

Acoustic sensors (20–100 kHz, SDT, UE Systems)

Early detection of pneumatic leaks & dry friction

10. Speed & Motion

Optical/magnetic encoders, laser Doppler

Micro-slip measurement & multi-drive web sync

11. Rheology/Chemistry

Inline viscometers, slit rheometers, pH probes

Fluid property tracking in slurries, polymers, paints

12. Radar Level/Volume

80 GHz FMCW radar, guided-wave TDR (E+H, Vega)

Buffer tracking; prevents pump cavitation

13. Machine Vision

8K/16K line-scan cameras (Basler, Dalsa, Keyence)

Direct correlation of surface defects with process drift

14. Thermal Imaging

IR microbolometer cameras (FLIR, Optris)

Cross-web thermal profiles & heating element hotspots

15. Atmosphere & VOC

Photoionization detectors (PID), NDIR analyzers

Solvent vapor safety (LEL) & drying efficiency

16. Cleanroom Metrics

Thin-film capacitive hygrometers (Vaisala)

Dew point down to -40°C & RH control in dry rooms

17. Laboratory QC

Destructive test fixtures, cup viscosity, solids

Bridges delayed lab results; validates AI causal models

Vendor-Agnostic PLC & Industrial Connectivity

PLCs: Siemens (S7-1500/1200, Sinumerik), Rockwell Allen-Bradley, Beckhoff TwinCAT, Fanuc CNC, Mitsubishi, Omron, B&R, and DCS (DeltaV, Experion, Centum).
Protocols: OPC UA, MQTT Sparkplug B, Modbus TCP/RTU, and CSV historian batch imports.
OT Security: Outbound-only TLS 1.3 architecture; zero inbound open ports; zero PLC writeback risk.

Core Value & Capabilities

Multivariate DPCA + CUSUM: Detects multi-sensor drift that univariate thresholds miss.
PackML State Gating: Evaluates only active production (EXECUTE), eliminating false alarms.
Schema-Validated AI: Google Gemini translates multivariate vectors into ranked root causes.
Closed-Loop Lab Reconciliation: Upgrades hypotheses to validated knowledge when lab results arrive.
Instant Time-to-Value: Built-in line simulator and automated CSV backfill require zero hardware retrofits.

Key Features

✓Continuous Multivariate Drift Detection (Dynamic PCA, Hotelling's T², SPE/Q, CUSUM)

✓Early Warning Quality Intelligence 15–45 Minutes Before Scrap Generation

✓Full Support for 17 Comprehensive Physical Sensor Families & Inline Metrology

✓PackML Machine-State Filtering (Zero False Alarms in Non-Production States)

✓Schema-Validated Google Gemini AI Root Cause & Prescriptive Actions

✓Closed-Loop Quality Reconciliation for Delayed Laboratory Test Results

✓Vendor-Agnostic Connectivity (Siemens, Rockwell, Beckhoff, Fanuc, DCS, OPC UA)

✓Per-Tag Contribution Attribution Isolating Driving Sensor Channels

✓Outbound-Only TLS 1.3 Telemetry Ingestion with Zero PLC Writeback Risk

✓Built-in Line Physics Simulator & Smart CSV Ingest for Instant Time-to-Value

Use Cases

Precision Slot-Die & Roll-to-Roll Web Coating (Electrodes, Optical Films)
Twin-Screw Polymer Extrusion & Sheet Compounding Quality Monitoring
Hot & Cold Calendering Roll Gap, Nip Force & Density Control
Continuous Slurry & Chemical Mixing Viscosity & Rheology Tracking
Closed-Loop Delayed Laboratory Quality Verification Reconciliation

Pricing Plans

Flexible

Metered Telemetry & Quality Intelligence (1,000 Data Points)

Predictable billing

Pay As You Go

€0.01/Unit

ProcessIQ — Industrial Process Intelligence & Predictive Quality Platform

About This Model