Process Optimizer

Process Optimizer by Quartic is an AI-driven process optimization application designed for manufacturers in life sciences, food and beverage, chemicals, and consumer packaged goods. It enables real-time optimization of batch and continuous manufacturing processes without requiring complex mechanistic models, digital twins, or large historical datasets — delivering measurable ROI in weeks rather than months.

Traditional process optimization approaches fall short in industrial environments: high-fidelity process models are expensive to build and maintain, deep learning systems demand large datasets and significant compute resources, and Model Predictive Control (MPC) systems chase setpoints rather than optimizing economic objectives. Process Optimizer addresses these gaps with a sample-efficient AI approach that works with as few as 10 prior batch runs or approximately one month of continuous process data, making it accessible to a wide range of manufacturing operations.

Core Capabilities

• Multiple Constraints Optimization: Simultaneously optimize multiple KPIs while applying process constraints — for example, maximizing yield while controlling moisture levels and energy consumption.
• Setpoint Recommendations: Instantly generate optimized setpoints to improve control precision and drive process efficiency in real time.
• What-If Scenario Prediction: Model what-if scenarios using control parameters to forecast and optimize process outcomes before making changes on the plant floor.
• Surrogate Model Approach: Quartic builds a surrogate model from historical setpoints and outcomes, eliminating the need for simulation models or mechanistic modeling expertise.
• Adaptive Process Control: Deploy adaptive control strategies across multi-unit systems and scale plant-wide without disrupting running processes.

Key Benefits and Differentiators

• Reduce batch-to-batch or shift-to-shift variability — customers have reported up to 79% reduction in batch-to-batch variability.
• Optimize with constraints without causing process disruption; recommendations are bounded within existing recipe and control limits.
• Reduce waste, recycle, and improve cycle time and quality consistency.
• Works with minimal historical data — as few as 10 prior batch runs for batch processes.
• No mechanistic models or large datasets required.
• Optimize multiple objectives simultaneously.
• Web-based deployment with no complex software installation; only a secure login is needed.
• ROI achievable in 90 days or less, with early results often visible within a few weeks.

Proven Real-World Outcomes

• Life Sciences: 15% faster freeze-drying cycle time, 50% reduction in unplanned downtime, 23% decrease in energy consumption, and 5% increase in product throughput.
• Food and Beverage: 20% reduction in moisture variability and 17% reduction in energy consumption in pet food drying operations.
• Life Sciences (Chromatography): 10% capacity uplift and 20% less variability in chromatography purification.
• 25% faster cycle time achieved with real-time quality monitoring and optimization.

Who It Is Designed For

• Process Engineers: Scale batch process optimization without digital twin complexity; test model efficacy with surrogate models using real process data, tune multiple KPIs with constraints on any unit operation, and deploy adaptive process control strategies plant-wide.
• Data Analysts: Access ready-to-use industrial datasets, apply models with faster validation cycles, and reduce model-to-impact lag time using clean, contextualized OT/IT data.
• Quality and Compliance Teams: Improve batch disposition and release time, ensure processes stay within control limits while optimizing yield, and maintain GxP compliance in pharmaceutical manufacturing environments.
• Reliability and Maintenance Teams: Integrate edge, cloud, and enterprise systems; maintain compliance and data lineage; and avoid vendor lock-in through open standards.
• Digital Transformation Leaders: Deliver enterprise-scale economic outcomes rather than isolated pilots, start small and scale with speed and confidence, and preserve and amplify the value of existing OT and MES software through Quartic's optimization layer.

Process Optimizer is a fully web-based application requiring only a secure login, with no on-premises installation needed. It is designed to integrate with existing OT and IT infrastructure, including edge, cloud, and enterprise systems, and supports GxP-compliant operations for pharmaceutical and life sciences manufacturers. The tool is part of Quartic's broader Industrial Intelligence platform, which also includes Industrial DataOps and additional applications for reliability, batch MVDA, and automated PAT.