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

Bringing deep expertise and real-world results to industrial challenges.

20+ Years hands-on experience
50+ Projects delivered
PhD in Control Systems
5 Languages spoken

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.

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.

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.

And much more

Need something specific? Feel free to ask. We tailor solutions to your problem, process and industry.

Let's talk about it

Publications

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

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Your Benefits

Concrete Results

  • More throughput at the same quality
  • Less energy consumption & waste
  • More stable processes despite disturbances & raw material variations
  • Faster commissioning, shorter trial times
  • Transparent decisions through data, models & simulation

Case Studies

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.

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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 for manufacturing, machine builders, process industry and energy generation.

Manufacturing

Guide operators or auto-adapt parameters when conditions change to reduce waste and raise throughput, by smart sensing and modeling relationships between desired parameters and environmental conditions.

Machine manufacturers

Optimize the way your machine operates, increase precision through perfect feedback loops and trajectory optimization; make it more resilient to perturbations, reduce component wear and lower energy requirements.

Process industry

Optimize mixing and processing, handle changing inputs, meet output quality and demand. Balance throughput, quality, energy and waste via advanced process control involving model-based predictive control and state estimation.

Energy generation

Increase energy yield while reducing component wear by damping oscillations through smart feedback loops and using model-based predictive control to optimize operation.

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.

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.

VFD Pump Tuning Tool →
Free online tool for tuning VFD-driven water pumps.

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
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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)

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.

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
Video call
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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
Germany

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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