We analyze process data in real time
and deliver predictions to operators and control systems.
Challenge: Changing operating conditions quickly reduce model performance.
In most cases, it doesn’t. Every hour of operation under suboptimal conditions creates measurable operational losses.
Operators react to deviations rather than anticipating them, adjusting process settings only when they move outside the expected range. Much of their knowledge remains undocumented and is lost when they leave the company.
As plant operating conditions change, static models lose accuracy and previously optimized process settings may no longer be optimal.
Plants collect large volumes of production data, but making use of it in real time requires time and tools that engineering teams often do not have.
No new sensors
No cloud
On-premise
Plant Optimizer integrates with your plant's data sources:
SCADA, AVEVA PI, historians, PLCs.
Models reflect the unique behavior of each process
and the interactions between different parts of the operation.
The system continuously predicts key process parameters,
helping operators make better decisions.
Model predictions can be integrated into control loops,
supporting automated process control.
Models adapt as operating conditions change,
maintaining their accuracy over time.
ORLEN
Challenge:
Diesel flash point could only be determined through laboratory testing, making real-time process adjustments difficult.
What we did:
We developed models that combine data from multiple refinery units to predict flash point in real time.
Result:
We achieved prediction accuracy within 3.5% of laboratory measurements, the models are accurate enough to be integrated into automated control.
KGHM
Challenge:
Optimizing a complex, variable process with only limited historical data available.
What we did:
We proved that our models can deliver value even with limited data and high process variability, winning technology competitions organized by KGHM.
Result:
Confirmed potential for process optimization and collaboration with one of the world's largest copper producers.
WASTEWATER TREATMENT
Challenge:
Unreliable measurement equipment made it difficult to use real-time measurements for process optimization.
What we did:
We developed a model that estimates key process variables in real time using existing plant data.
Result:
Real-time process optimization and reduced energy consumption without installing additional sensors.
A platform for building, deploying, and managing industrial models.
System architecture and functionality.
Plant Optimizer runs on-premise, within the customer's own infrastructure. Production data never leaves the plant and is not sent to the cloud or external servers. This is a deliberate design choice.
Built-in integration with AVEVA PI System
Connects to existing SCADA systems via REST API
Works with both historical and real-time data
No need for additional sensors
No need to replace existing infrastructure
No cloud connection required
Plant Optimizer runs within the customer's infrastructure, keeping production data inside the organization.
Works with data from your existing systems - no new sensors or infrastructure required.
Models capture real plant behavior and dynamically adapt to changing operating conditions.
We start with a data analysis to identify the potential for optimization.
Yes. Plant Optimizer runs entirely on-premise, within your plant's infrastructure. No data is sent to the cloud or outside your organization. Anzonia works as a technology partner within your environment, using your existing resources.
In most cases, no. We use data you already collect through SCADA, PLCs, or historians. Avoiding the need for additional CAPEX is a key principle of our implementation approach.
We start by analyzing your historical data and assessing the potential for optimization. No commitment, no sales pitch - just a technical discussion.
A typical pilot takes 4-8 weeks, starting with an analysis of historical data. Full deployment depends on the complexity of the process and available data. We focus on validating measurable results rather than rushing deployment.
Plant Optimizer works alongside your automation and IT teams. It processes hundreds of parameters simultaneously, identifying relationships and patterns that are difficult to assess manually. Your specialists remain responsible for decisions, with the system providing additional information to support them.
Plant Optimizer works wherever complex continuous processes generate process data - including refineries, steel mills, mining, wastewater treatment, energy, and chemicals. If you don't see your industry listed, get in touch. We can assess the potential using your historical data.
We don't ask you to take it on faith. We start with your historical data and assess the potential for measurable improvement. If the potential isn't there, we'll tell you. We recommend moving forward only when there is a clear business opportunity for your plant.
We'll analyze your process, identify opportunities for improvement, and show you where you can achieve greater efficiency, safety, and control.
Response within 24 hours
No commitment
A practical discussion
about your process
We'll analyze your process, identify opportunities for improvement, and show you where you can achieve greater efficiency, safety, and control.
Response within 24 hours
No commitment
A practical discussion about your process
We'll analyze your process, identify opportunities for improvement, and show you where you can achieve greater efficiency, safety, and control.
Response within 24 hours
No commitment
A practical discussion about your process
We'll analyze your process, identify opportunities for improvement, and show you where you can achieve greater efficiency, safety, and control.
Response within 24 hours
No commitment
A practical discussion
about your process
