APCPerformance & Intelligence
Advanced Process Control
Every loop at its best operating point, all the time. AI-driven advanced process control that adds machine learning, reinforcement learning and neural networks to your PID and model predictive control layers, adjusting setpoints in real time for complex, nonlinear processes.
The challenge
PID loops and linear model predictive controllers are tuned around a single operating point. When feed quality, product grades, ambient conditions or equipment wear change, fixed models drift, operators fall back to conservative setpoints, and energy, yield and quality are left on the table. Key quality variables often arrive hours later from the laboratory, long after the process has moved on.
Overview
Our Advanced Process Control (APC) solution upgrades the control layer you already have rather than replacing it. It works above your PID loops and model predictive controllers, adding adaptive AI: machine-learning models, reinforcement-learning agents and neural networks that learn how your process really behaves and continuously adjust setpoints for flows, temperatures and pressures in closed loop.
Classical linear control breaks down on multi-input, multi-output processes and on complex chemical or physical reactions. APC handles these nonlinear dynamics directly, and AI soft sensors estimate variables that are hidden or delayed, such as laboratory quality results, from live sensor data and process history, so control can act on quality while the product is still being made.
Every control strategy is proven before it touches the plant. Ghost and simulation modes run digital twins or physics models at high speed to test control actions safely, and only proven strategies are switched to closed loop. APC draws on historian data for training and works alongside our Industrial Data Historian, Energy Management and SPC applications.
Capabilities
What APC does
Closed-Loop Optimisation
- Adaptive AI agents in place of fixed models
- Setpoints for gas flows, temperatures and pressures adjusted in real time
- Operating limits and constraints applied to every move
- Works above existing PID loops and MPC
Nonlinear & Multivariable Control
- Multi-input, multi-output (MIMO) control
- Nonlinear dynamics and complex chemical or physical reactions
- Machine learning, reinforcement learning and neural networks
- Steady control through grade changes and varying feed
AI Soft Sensors
- Real-time estimates of hidden or delayed variables
- Laboratory quality predicted from sensor fusion and process history
- Virtual metrology for properties measured offline
- Estimates used directly by the controller
Ghost & Simulation Modes
- Digital twins or physics models run at high speed
- Control actions tested safely before going live
- Strategies compared with current control
- Proven strategies promoted to closed loop
Chemicals & Refining
- Grade transitions
- Distillation column optimisation
- Batch reactor temperature control
- Energy-intensive units run closer to their limits
Manufacturing, Food & Semiconductors
- Drying, grinding and refrigeration optimised for less energy
- Less scrap and waste from tighter control
- Virtual metrology to reduce film thickness variation
- Less variation in chemical vapour deposition
Benefits
Why manufacturers choose APC
Stable at the optimum
Setpoints follow the process continuously instead of sitting at conservative margins.
Control where linear models fail
Nonlinear, multivariable processes are controlled as they really behave.
Quality in real time
Soft sensors estimate laboratory results while production runs, so control acts before off-spec product is made.
Less energy, scrap and waste
Tighter control reduces energy use, scrap and rework.
Safe adoption
Every strategy is proven in simulation before it moves a real setpoint.
Builds on what you have
Works with your existing control layer, from PID loops to model predictive control.
Ask APC in plain language
LS Assistant, the AI assistant in every Logical Systems application, answers questions from your live APC records and shows the sources behind every answer. It keeps learning as your records, work instructions and resolved issues grow, and your data is never used to train AI models.
Answers with sources
Every answer cites the records and work instructions it used.
Your role, your site
It sees only what each user is allowed to see.
Asks before it acts
Every change it proposes needs a person's confirmation and is audited.
18 languages, voice on mobile
Questions, answers and content in your teams' languages.
Integration
Connects to the systems you run
Systems & protocols
- DCS
- PLC
- Model predictive control (MPC)
- Industrial Data Historian (IDH)
- LIMS
- OPC UA
- Digital twins and simulators
Walkthrough
See APC working with scenarios from your own plant, guided by one of our engineers.
Talk to an engineerWorks with
Related solutions
See APC in action
Book a demo with our engineers, using scenarios from your own plant.