Industrial AI and Advanced Process Control

APC/MPC, state estimation, mathematical optimization and digital twins - from diagnostic to deployment, and beyond: long-term maintenance, tuning and knowledge transfer to keep performance high over time.

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Process industry - control room
Process industry Reducing energy use and waste, adapting to changing input quality and output demands, and balancing throughput, quality and energy.
Manufacturing - automated line
Manufacturing Tools that guide operators or automatically adapt parameters when conditions change, reducing waste and increasing throughput while keeping quality stable.

Proven Track Record

PhD-level theory combined with 20+ years of live MPC deployments — across process industry, energy, and autonomous systems.

20+ Years hands-on experience
50+ Projects delivered
PhD in Control Systems
5 Languages spoken
  • Former MPC engineer at CERN (LHC superfluid helium at 1.9 K), IAV GmbH (wind turbine pitch control), SkySails Power (airborne wind energy), and evosoft (Siemens Corporate Technology)
  • 4× MSc in Control Engineering (Grenoble INP, Karlsruhe Institute of Technology, Gdańsk University of Technology) and PhD from University of Valladolid — trained at four top European engineering schools
  • Industries covered: particle physics cryogenics (CERN), wind energy (IAV, SkySails), industrial SCADA (evosoft/Siemens), and aerospace HIL simulation (Assystem Group, A400M turbine engine)

Competence demonstrated in Past Projects

Deep theoretical foundation plus many years of hands-on practice in R&D contexts, developing new types of systems where the solution is not obvious at the start. We adapt language to the audience and deliver key insights in a compact and engaging way.

Feedback loop design and tuning

PID, cascade, feedforward and ratio control — structured loop design, identification, tuning and commissioning for stable, responsive and robust closed-loop operation.

APC and MPC

Advanced controls enable efficient operation of non-linear systems with strong couplings, operated across a wide range of conditions under strict constraints.

State estimation

Combine models with available sensors to improve accuracy, reduce the need for expensive sensors and estimate non-measurable variables.

Optimization and trajectories

Scheduling, logistics and resource allocation at plant level, and trajectory optimization for machines to increase throughput, reduce wear and lower energy costs.

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Modeling and simulation (digital twins)

Evaluate ideas and operating strategies without touching production. Parametric/sensitivity studies guide investment; models enable optimization and operator training.

Operator simulators

Train operators offline to reduce interruptions and waste. Cover standard tasks, complex situations and safety-critical scenarios.

Workshops and courses

PhD-backed teaching and hundreds of public talks. Key knowledge delivered compactly and engagingly, tailored to experts, decision makers or technicians.

Tools and stack

Cutting-edge, industry-standard tools chosen per application. Seamless integration with existing software and collaboration via version control.

Publications

Peer-reviewed papers, conference proceedings, and theses on Model Predictive Control, state estimation, and cryogenics at CERN.

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Products

VFD Pump Tuning Tool

A guided web wizard for complete VFD configuration of booster pump systems. Enter a few on-site measurements — the tool calculates all 30+ VFD parameters tailored to your specific installation. Covers PID settings, analog input scaling, sleep/wake thresholds and motor identification. Free, online, mobile-friendly. No engineering background required.

VFD Pump Tuning Tool →

Your Benefits

Concrete Results

  • More throughput and faster cycle times at the same quality
  • Lower energy, fuel and raw material cost; reduced waste and emissions
  • More stable processes despite disturbances, varying inputs and model uncertainty
  • Reduced component wear, actuator fatigue and maintenance cost
  • Price-optimal operation — adapt in real time to energy prices, demand and market signals
  • Safety-guaranteed automation — force limits, obstacle clearance and collision avoidance by design
  • Faster commissioning and shorter trial times
  • Transparent, auditable decisions through data, models and simulation
  • Lower dependency on scarce specialists — advanced automation handles complex tasks around the clock without requiring expert operators on every shift

Design Patterns

Published references showing how APC/MPC technology delivers measurable results across industries.

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Calculate Your Potential Savings

See how much you could save with Advanced Process Control. Enter your approximate annual costs below.

Input your parameters

€/year
€/year
€/year
€/year

Potential Annual Savings

Energy reduction €75,000 10-15%
Waste reduction €40,000 15-25%
Throughput increase €100,000 3-8%
Downtime reduction €20,000 15-25%
Total annual savings €235,000
Typical payback period: 6-12 months
Get a concept + ROI estimate in 10 days

Estimates based on typical industry results. Actual savings may vary.

Send your historian data for a quick feasibility estimate (NDA-ready) We sign NDAs before receiving any data.

Industries

Focused on practical results across manufacturing, process industry, energy, robotics, logistics and machine building.

Manufacturing & CNC

Reduce cycle time and raise throughput on CNC machining, robotic milling and assembly lines. Contour error compensation, feed-rate optimization and deflection prediction cut scrap and raise surface quality.

Machine Builders

Embed trajectory optimization and model-based control to increase precision, reduce component wear and lower energy draw — with embedded solvers meeting hard real-time budgets on standard PLCs or microcontrollers.

Process Industry

Handle nonlinear batch and continuous processes — chemicals, pharma, cement, steel and food. When large disturbances, operation close to constraints, or model mismatch cause the control system to operate uneconomically during transients — and RTO setpoints lose validity — Economic MPC embeds the economic objective directly into the feedback loop.

Energy, Buildings & Agriculture

Maximize renewable energy yield, dispatch battery storage for price arbitrage, cut building HVAC energy by 17%+, and minimize greenhouse heating cost — with time-varying prices and weather forecasts built into the controller.

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Robotics & Autonomous Systems

Control collaborative robots to ISO 15066 force limits, plan collision-free motions for manipulation and assembly, and operate legged or wheeled robots across unstructured terrain — constraint satisfaction guaranteed by design.

Logistics & Intralogistics

Optimize AGV routing and speed profiles in warehouses, reduce crane sway, synchronize multi-robot fleets and replan paths in real time under uncertainty. Constraint-aware MPC replaces conservative fixed-speed profiles.

Aerospace, UAV & Marine

Guidance and control for drones, UAV swarms, underwater vehicles and ships — from time-optimal trajectories to dynamic positioning and fault-tolerant attitude control under actuator saturation and model uncertainty.

Electric Drives & Power Electronics

Predictive torque and current control for VFDs, switched reluctance and permanent magnet motors. Reduce torque ripple, extend lifetime and meet grid fault ride-through requirements in turbomachinery, oil & gas and industrial drives.

Schedule a plant-wide control performance audit

Ready to improve your process?

Book a free 30-minute consultation to discuss your challenges.

Book a 30-min feasibility call No commitment required

How we work (in 4 steps)

1

Audit & Diagnosis:

Clarify data, goals & constraints; identify quick wins.

2

Simulation & Concept:

Digital twins, first MPC/estimators; prove potential.

3

Pilot & Tests:

Proof-of-concept on process/machine, tune parameters.

4

Scaling & Operation:

Industry-grade implementation, training, tuning & support.

Agile in 2-week sprints – with clear, usable deliverables after each sprint.

Services

Four engagement types with clear scope, high-quality execution and professional standards. Remote or on-site.

Consulting

Consulting

Uncover bottlenecks and opportunities using data analysis, on-site observations and feedback from your team. From insights to business cases and a practical roadmap.

Software development

Software development

20 years across the full lifecycle: requirements, architecture, implementation, testing, deployment and documentation on PCs, industrial systems, SCADA and embedded.

Training

Training & Coaching

Hundreds of talks in five languages. Operator training with digital twins; engineer training in advanced control, state estimation, optimization; team mentoring.

HR Services

HR services

Provide the technical expertise to assess and hire the right people, leveraging a broad network to find strong candidates.

Approach tailored for SMEs

Tailored + standards

Custom solutions where it matters, and standard tools where they fit best.

Flexibility & quick response

Short reaction times and pragmatic delivery to keep momentum.

Long-term commitment

Maintenance, tuning, support and knowledge transfer to sustain performance.

Hands-on

Data analysis plus workshops with operators and management to uncover real problems.

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Model-based

Use simulation and optimization to save experimental time and reduce risk during development and commissioning.

Risk management

Carefully weigh risks and benefits; enable progress via controlled trials of new parameters and approaches.

Agile development

Two-week sprints with usable results each time; quick adaptation to changing requirements and experimental findings.

Deep theory, applied

Strong foundations in mathematics, physics, computer science, control systems and optimization - applied to real problems.

Starter packages

Agile execution in two-week sprints across all packages, including clear deliverables after each sprint.

Most Popular

Diagnostic and analysis

Understand the problem, data and objectives; identify quick wins and a sensible path forward.

Deliverables: analysis report + concise technical proposal.

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Simulation study

Recreate the setup in simulation, build first models/estimators, run realistic studies to assess potential.

Deliverables: simulation study report + draft plan for experimental proof of concept.

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Experimental proof of concept

Bring simulation into reality, run controlled tests, adapt parameters and validate performance on site.

Deliverables: test plan + on-site report + tuned settings.

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User-facing tools

Engineering aides or operator-training tools based on models; designed for non-experts.

Deliverables: working prototype + brief user guide.

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Industry-grade development

Harden to industrial standards with documentation, safety and quality gates - ready for scale.

Deliverables: codebase and docs aligned with agreed standards.

Commissioning

Deploy on the machine or process. Operator training, extensive testing and final documentation.

Deliverables: commissioning report, training materials, SOPs.

Support

Maintenance, tuning, adaptations and knowledge transfer - ongoing or punctual.

Deliverables: per-sprint updates and improvement notes.

Customer-requested package

Defined jointly upon agreement to match your specific needs and constraints.

Deliverables: as agreed, per-sprint outcomes and documentation.

Cooperation Models & Pricing

Below you will find typical cooperation models as they are practical in the technical SME sector (engineering/development/plant environment). The daily rates shown are starting prices ("from") net plus VAT and will be specified in the offer based on the specific project context.

1

Model 1 — Initial Development Phase: Full-time On-Site (Ramp-up)

Purpose: Maximum progress in short time (kick-off, system access, fast iterations, on-site tests/integration).
Mode: Full-time, 5 days/week on-site.
from €990/day
2

Model 2 — Hybrid Full-time: Mostly Remote + Scheduled On-Site Weeks

Purpose: High velocity with reduced on-site share; regular, predictable presence for reviews, tests, and acceptance.
Mode: ~80% remote, 1 week on-site every 5 weeks (full-time on-site).
from €790/day
3

Model 3 — Long-term Part-time Support: Topic Ownership & Continuous Improvement

Purpose: Sustainable ownership without full-time headcount; stabilization, continuous improvement, knowledge transfer.
Mode: 20 hrs/week, ~80% remote, 1 full-time week on-site every 10 weeks (e.g., for reviews, tests, integration).
from €490/day
4

Fixed Price / Milestone-based Payment (Work Contract Logic)

Suitable for: Clearly defined deliverables with defined acceptance (e.g., analysis package, model audit, MPC concept, prototype, optimization module).
Billing: Fixed price per milestone/package; acceptance based on clear criteria.
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Agile Working Methods & Delivery Cycles (Standard)

Regardless of the billing model, development is agile:

  • 2-week cycle with result delivery (demo/review + next priorities)
  • Transparent progress (backlog, sprint goals, KPI tracking as needed)
  • Early feedback for risk reduction (technology, integration, acceptance)

Additional Models (optional, depending on scope)

Retainer / Service Contingent (optionally with response times)

Suitable for: Plannable capacity, regular reviews, quick support ("keep-the-lights-on" + minor enhancements).

Billing: Monthly contingent (e.g., X days/month), optionally with defined response times.

Scoping Sprint (Workshop → Reliable Offer)

Purpose: Quickly clarify scope, make risks/dependencies visible.

Result: KPI target picture, system boundaries, data/interface list, integration plan, effort estimate, and offer model (T&M or milestones).

Build–Operate–Transfer (Setup → Operation → Handover)

Purpose: Quick external start, then internal anchoring.

Service: Setup, stabilization, knowledge transfer, optionally recruiting support (role profile, interview support) and structured onboarding of internal owner.

A Quick Cost Comparison (Internal FTE vs. External)

An internal FTE with a €100,000 gross salary costs the company (roughly calculated) about ~€720 per productive day.

Internal FTE calculation example:

  • Employer costs (simplified): ~€120,000/year (salary + employer contributions)
  • + conservative overhead (IT/workplace/management/HR, tools, etc.): +20% ⇒ ~€144,000/year
  • Productive days (e.g.): ~200 days/year (working days minus vacation/sick leave/training/other absences)

→ Internal full cost per productive day: 144,000 / 200 = ~€720/day

Price Factors (why "from" pricing makes sense)

The specific conditions typically depend on:

  • Geography & travel: Travel, accommodation, expenses
  • Urgency / availability: Express start, downtime situations, weekend windows
  • Predictability & duration: Contingents/long-term enable better conditions
  • On-site share & rhythm: Predictable vs. ad-hoc
  • Complexity & criticality: Production risk, safety/quality constraints, commissioning
  • Scope clarity: Clearly defined deliverables vs. open R&D questions
  • Tooling & compliance: Access, data situation, IT/OT requirements, documentation scope
  • Response times / SLA: Agreed response times
  • IP/rights arrangements: License, source code, exclusivity

Contract & Compliance Components (typical)

  • NDA (confidentiality) as needed
  • DPA (Art. 28 GDPR), if personal data is processed
  • Clear arrangements for acceptance, change requests, payment terms, travel costs, liability framework (project-specific)

IP, Licensing & Exclusivity Options (on request)

Depending on the project, cooperation can also be structured as Solution-on-Demand:

  • Delivery of a ready-to-use solution (e.g., software module/algorithm component/toolchain).
  • Typical distinction between customer-specific results (for the customer) and reusable generic IP (methodology, libraries, building blocks).
  • Optional: License/usage rights model (e.g., per site/plant/module or enterprise license) incl. maintenance/updates via retainer.
Optional customer protection (competitor restriction):

It can be agreed that we will not sell or license the developed solution to direct competitors of the customer (e.g., as industry/competitor exclusivity for a defined period and/or market), with scope and limits to be precisely defined contractually.

Conclusion

The models above are proven standards — individual structures are also possible. Whether daily rate, milestones, retainer, license model, or exclusivity: We design the cooperation to fit scope, risk, budget, and your procurement/compliance process.

The cooperation possibilities are practically unlimited – we will find a clean, fair way.

Note: This page is for general information and does not constitute legal advice. The specific terms are bindingly regulated in the respective offer and contract.

Book a Free Consultation

Schedule a 30-minute call to discuss your process challenges and explore potential solutions.

What we will cover:

  • Review your current process challenges
  • Identify potential for APC/optimization
  • Discuss practical next steps
  • Answer your technical questions
30 minutes
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APC Readiness Assessment

Answer 5 quick questions to evaluate if your process is ready for Advanced Process Control.

Question 1/5

How would you describe your current process data collection?

Question 2/5

How stable is your current process operation?

Question 3/5

What is your process control maturity?

Question 4/5

How clear are your optimization objectives?

Question 5/5

What is your team capacity for new technology?

Excellent APC Readiness!

Your process shows strong potential for Advanced Process Control.

Your readiness score: 0 /15
Get in Touch Book a Call

Blog

Short and clear: practical notes on control, optimization and digitalization.

MPC in 5 Minutes

Why predictive control delivers robust quality.

Jan 23, 2026

Digital Twins Done Right

Where simulation brings real ROI.

Coming soon

Operator Simulators

Avoid production stops & build competencies.

Coming soon

Frequently Asked Questions

Common questions about Advanced Process Control and working together.

What is Model Predictive Control (MPC)? +

MPC is an advanced control strategy that uses a mathematical model of your process to predict future behavior and optimize control actions. It excels at handling multi-variable systems with constraints, delivering better performance than traditional PID control.

How long does an APC implementation take? +

Timelines vary by scope. A diagnostic phase typically takes 2-4 weeks. A full proof-of-concept can be completed in 2-3 months. We work in agile 2-week sprints with deliverables at each stage.

What ROI can you expect from APC? +

Typical results include 5-15% energy savings, 10-30% throughput increase, and significant waste reduction. ROI is often achieved within 6-12 months depending on the application.

Do you work remotely or on-site? +

Both. Many phases can be done remotely, including data analysis, model development, and simulation. On-site presence is valuable for commissioning, operator training, and initial diagnosis.

What industries do you work with? +

Process industry (chemicals, pharma, food & beverage), manufacturing, machine builders, and energy generation. Any industry with complex, multi-variable processes can benefit.

Have more questions?

Ask directly
Free Resource

APC Readiness Checklist

Assess if your process is ready for Advanced Process Control. A practical guide with 15 key questions.

  • Evaluate your data infrastructure
  • Identify quick-win opportunities
  • Understand resource requirements
Download PDF No email required Request an APC Readiness Check (15-min intake)
Live Event

Free Webinar: Introduction to APC

Learn how Advanced Process Control can transform your operations

  • What is APC and when does it make sense?
  • Real-world case studies and ROI examples
  • How to evaluate APC readiness
45 min + Q&A
Online via Zoom

We will send you the Zoom link before the event

Contact

Send a message

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Direct contact

Dr. Rafał Noga

Call: +49 175 617 6792 E-mail: rafal@noga.es

Meeting

Suggest a 30-minute video slot by e-mail. Available EN/DE/FR/ES/PL.

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