In many industrial plants, a significant number of control loops and process systems continue to operate below their optimal performance levels. This can lead to process variability, excessive raw material and energy consumption, and reduced production efficiency. Valmet’s PID Tuning and Process Control Services (formerly Expertune) help identify control loops that are limiting operational performance and provide targeted optimization solutions. By improving control performance, these services help stabilize processes, increase productivity, reduce operating costs, and maximize overall plant efficiency.

Hidden PID performance issues are quietly driving up operating costs

Many process and manufacturing plants lose millions of dollars each year due to poorly performing control systems. Industry experience shows that approximately 20-30% of control loops are operating in manual mode, while up to 85% of control loops are not optimally tuned.

In addition, 20-40% of controllers experience persistent oscillations, increasing process variability, reducing equipment reliability, and negatively impacting production performance. With so many issues occurring simultaneously, it can be challenging to monitor, prioritize, and identify the root causes of performance problems.

Valmet’s control performance experts provide comprehensive solutions to address these challenges. Our PID Tuning and Process Control Services help identify improperly configured control loops, uncover root causes, and implement effective corrective actions to improve control performance and optimize overall plant operations.

PlantTriage

PlantTriage is a continuous control loop optimization and performance monitoring software that proactively identifies and alerts users to process control issues as soon as they occur across the plant.

Developed by a team of control experts with hundreds of years of combined industry experience, this award-winning solution goes beyond PID tuning. It provides deep insights into control system performance, helping plants improve process stability, enhance operational efficiency, reduce variability, and maximize overall production performance.

Global Loop Optimizer SaaS

Global Loop Optimizer SaaS delivers world-class PID optimization and tuning capabilities across all plants within an organization.

This solution is ideal for companies operating multiple facilities and managing more than 100 control loops, enabling standardized control performance, improved operational consistency, and optimized process efficiency across the entire enterprise.

PID Loop Optimizer

PID Loop Optimizer is a PID tuning software designed for individual plants or facilities with fewer than 100 control loops requiring optimization.

By replacing trial-and-error tuning with a systematic, data-driven approach, the solution helps stabilize processes quickly, improve control performance, and enhance overall operational reliability.

Control performance services

Control Performance Service is a comprehensive turnkey solution for plants experiencing operational performance challenges or underperforming control systems.

From assessing current conditions and identifying root causes to implementing improvement actions, Valmet provides a complete roadmap to help manufacturers increase production efficiency, improve process stability, and reduce operating costs.

Control performance evaluation

Control Performance Evaluation provides an in-depth assessment by Valmet’s control experts, giving organizations a clear and comprehensive understanding of their control system performance, including:

• Areas within the control system that are experiencing performance issues.
• The impact of these issues on production output, operational efficiency, and manufacturing costs.
• Improvement opportunities that offer the highest potential return on investment.

With these insights, companies can develop data-driven optimization strategies, prioritize the most impactful improvement initiatives, and maximize the value of their operational and capital investments.