Industrial AI and Advanced Process Control

Replace drifting loops and conservative setpoints with model-based predictive control — APC/MPC, soft sensors, digital twins, real-time optimization.

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.
Experience at
· · · ·
Previous positions, not client endorsements.
Tools & Platforms
Python · MATLAB / Simulink · C / C++ · CasADi / acados · WinCC OA

The Industrial AI Stack

Industrial AI is a layered stack — not a single product. Each layer builds on the one below, and each has documented ROI of 6–18 months. A diagnostic call identifies which rung your plant is on and the fastest path to the next one.

Layer 7 Digital Twin

Live virtual replica of your plant — model + state estimation + RTO/MPC integrated. Enables what-if analysis, operator training, and enterprise optimization.

Explore →
Layer 6 Real-Time Optimization (RTO / DRTO)

Compute the economically optimal operating point every 30 minutes. $1–15M/year per major process unit. Requires APC as executor.

Explore →
Layer 5 APC / MPC / NMPC

Multivariable closed-loop control — track optimal setpoints, handle disturbances, enforce constraints. Payback 3–12 months.

Explore →
Layer 4 Predictive Maintenance

Detect bearing wear, fouling, and equipment degradation from vibration, acoustic, and current data. Deployable independently of the process control stack.

Explore →
Layer 3 Process Monitoring — SPC / MSPC / FDD

Detect process drift and abnormal events before they become quality failures. Prerequisite to deploying APC.

Explore →
Layer 2 Soft Sensors & State Estimation

Estimate unmeasured quality variables and synchronize models with the plant in real time. Enables tight quality control without expensive analyzers.

Explore →
Layer 1 Measurement & Data Infrastructure

Sensors, analyzers, historian (AVEVA PI, OPC UA). The foundation — without clean data, nothing above it works.

Which rung is your plant on?

A 30-min diagnostic call maps your current position and the fastest path to measurable ROI.

Book a Diagnostic Call

Proven Track Record

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

20+ Years hands-on experience
30+ APC/MPC projects
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)

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
Video call
EN/DE/ES/FR/PL

Select a Time

Choose a time that works for you

Open Calendar
Or send an email:

Case Studies

Selected project summaries — all under NDA, anonymised by default.

View all case studies →

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.

Show more competences

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.

Show more publications
Writing a paper?
Cite our work with properly formatted BibTeX entries.
Download BibTeX

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
Service

Deployment Toolchains for Scalable Automation

When complex control logic must be adapted and deployed across many machine variants or installations, rebuilding it manually is the bottleneck. I build engineering toolchains that turn structured configuration into deployable artifacts: controller settings, PLC code, HMI objects, tests, commissioning checklists, and documentation — consistently, with fewer errors, faster.

The toolchain generates:
  • Controller configuration and parameter sets
  • PLC code skeletons and deployment packages
  • HMI objects, alarm structures, I/O mappings
  • Tests, simulation assets, commissioning checklists
  • Operator and engineer documentation
Good fit when:

The same engineering pattern repeats across projects; commissioning is slow or error-prone; knowledge is concentrated in a few experts; quality varies between sites or machine variants.

"First stabilize the engineering logic — then industrialize it."

Discuss your engineering workflow

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: 6-18 months

Get a personalized feasibility study

We reply with a tailored analysis within 2 business days.

Ranges based on published industrial implementations (steel, cement, HVAC). Results vary by process. See sourced case studies →

Free 1-Page Process Diagnostic

Send us one week of historian data and we will return a concise 1-page diagnostic report: bottleneck identification, control loop health, and a realistic improvement estimate — at no cost and no commitment.

NDA signed before data exchange. Results delivered within 5 business days.

Request free diagnostic

Industries

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

Paraglider & Kite-Based Systems

Flight state estimation and closed-loop control for paragliders and kite-based systems — observer design, stability augmentation, and autonomous guidance, backed by 1,000+ hours of hands-on paraglider flight.

Learn More →

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.

Learn More →

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.

Learn More →

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.

Learn More →

Show more industries

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.

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.

Learn More →

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.

Predictive Maintenance

Detect bearing wear, gearbox degradation, and blocked filters from live sensor data — before failure occurs. Often as simple as a microphone and suitable signal processing.

Learn More →

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.

Show more

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.

Practical Model Development

Models as simple as possible — geometry and basic physics for linear control design, minimal nonlinear extensions only when simulation demands it. Complexity is justified by the control problem, not assumed.

Learn More →

Startup Offer: Senior Control & Autonomy Support

Compact, clearly scoped work packages (5–10 days) and light-touch support — so you keep development in-house, protect your IP, and build no long-term external dependencies.

For startups bringing complex dynamic systems to real-world operation: drones, robotics, aerospace, mobile machines, energy tech, industrial automation. Remote-first, occasional on-site possible.

Mini Implementation Packages (5–10 days)

Prototype of an estimator or controller, simulation/test harness (SIL/HIL), critical module refactoring, experiment design + on-site test days + evaluation report.

Technical Sparring Partner

60–90 min review call weekly or biweekly while your team implements. Focus: architecture, controller concept, robustness, estimator design, test design, log analysis. Written notes with decisions, risks, and next steps.

Gate Reviews (milestone-based)

3–5 jointly defined gates (e.g. "before first field test", "after stable closed-loop", "before scaling"). Per gate: review + written findings + Go/No-Go recommendation + risk register.

Enablement / Training

1–2 compact workshops tailored to your system: architecture paths, sensor/IMU integration, observers/filters, vibration damping, loop shaping, test design, KPI definition, tuning workflow. Deliverable: training materials + playbook.

NDA standard. You keep IP ownership and control of development. No hidden licensing. Transparent fixed-price or day-rate billing to match your budget. Always handed over so your team can continue independently.

📅 Book a 20-min intro call

Goal, constraints, status, risks — then a concrete proposal.

Starter packages

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

User-facing tools

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

Deliverables: working prototype + brief user guide.

Show more packages

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.
Show more cooperation models

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.

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

Blog

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

From Tribal Knowledge to Scalable Automation: Why Deployment Toolchains Are the Real Productivity Unlock

Many manufacturers don't lose time because the control algorithm is too hard. They lose time because the path from expert knowledge to deployed engineering is too manual. Deployment toolchains fix that — and Siemens, Beckhoff, Rockwell, and MathWorks are already proving it.

Mar 25, 2026 · 12 min

Neural Networks in Industrial Control: How Many Are Actually Running?

The AI revolution is real — but how many neural networks are actually running industrial control loops? Analysis of 672 studies, 148 real-world implementations, and 10 confirmed production deployments reveals the gap between hype and hardware.

Mar 23, 2026 · 14 min

Something Happened to APC in August 2025

Google Trends shows a 5–10× synchronized jump in searches for advanced process control, digital twin, and soft sensor in August 2025. Here is the timeline that explains it.

Mar 17, 2026 · 12 min

MPC in 5 Minutes

Why predictive control delivers robust quality.

Jan 23, 2026 · 5 min

5 Signs Your Control Loops Are Costing You Money

Most process plants quietly lose 5–15% of throughput and energy efficiency through poorly tuned loops. Here are the five symptoms to look for — and what each one costs.

Mar 21, 2026 · 8 min

Soft Sensor vs. Hard Sensor: When to Use Which

A practical decision framework for choosing between physical analyzers and model-based virtual sensors — with cost ranges, lag times, and the hybrid approach most plants miss.

Mar 21, 2026 · 7 min

How to Decide if APC Is Worth It: A 15-Minute Self-Assessment

Before spending on a consultant or a commercial APC platform, run through this checklist. It identifies whether your process has the prerequisites for advanced control.

Mar 21, 2026 · 10 min

Read more →

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? +

Published reference implementations report: ~17% primary energy reduction in buildings (ETH Zurich / Siemens, IEEE TCST 2016), temperature variability halved in cement kilns (Holcim / ABB, 2008), and slab quality out-of-spec cut from 59% to 12% in steel reheating furnaces (Dillinger, 2011). Reference payback periods: 6–18 months. Every process is different — a 30-minute discovery call is the fastest way to estimate the realistic opportunity for your system.

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.

Can you sign an NDA before I share data? +

Yes — a mutual NDA is standard practice and we sign before any data or process details are shared. We work comfortably in export-controlled and security-sensitive environments.

What if the project doesn't deliver the expected results? +

We structure every engagement in phases with clear deliverables and exit points. If a phase shows the expected benefit is not achievable, we say so — and stop — rather than continuing to invoice. A failed proof-of-concept early is far cheaper than a failed deployment late.

Can you work with our existing SCADA / DCS / ERP? +

Yes. We work at the data layer — if your historian or data infrastructure exports standard formats (OPC-UA, CSV, REST), we can interface with it regardless of DCS or SCADA vendor. PLC-level and vendor-specific control system integration requires collaboration with your automation team or vendor.

Who owns the IP and code developed during the project? +

The code and models developed remain the intellectual property of Dr. Noga. The client receives a perpetual use license included in the development price. Exclusive licenses and non-compete agreements (NCA) are available and negotiable. Details are defined in the contract.

Do you work alone or with a team? +

Primarily alone — which means senior-level attention on every task, no junior handoffs, and no account-manager overhead. For projects requiring additional capacity, I have a trusted network of specialist engineers I can bring in under the same quality and confidentiality standards.

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
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

Opens your email client with pre-filled message

Your data is processed by FormSubmit.co and used solely to respond to your inquiry. No marketing without consent.

Direct contact

Dr. Rafał Noga

Meeting

Book a free 30-minute video call directly via Calendly.

Book on Calendly

Stay Updated

Get insights on Industrial AI, APC, and process optimization delivered to your inbox.