Control the Impossible

Optimization for physical processes. Higher yield, lower energy, failsafe in under one second. Proven first on chemical reactors.

Book a discovery call How it works
>2%
Yield Improvement
~10%
Energy Reduction
<100ms
Failsafe Response
The problem

You've optimized this reactor before. You'll do it again next year.

Every plant has been through advanced control projects. Most have working APC on at least some loops. The problem isn't that optimization doesn't exist. It's that it doesn't compose. Each project rebuilds the same primitives. The model is bespoke. The controller doesn't transfer. The improvement decays as the process drifts. Eighteen months and several million dollars later, you have a slightly better version of what you started with, and the next reactor needs its own project from scratch. A lot is being left on the table.

How it works

Optimization that reads the process

Acaysia describes your process as data, then optimizes against it in real time. The same four steps run whether the unit operation is a reactor, a column, or a dryer.

Step 01

Model the process

Acaysia builds a model of your process from your plant data and known physics. That model is what the controller optimizes against.

Step 02

Optimize in real time

Every cycle, the controller simulates thousands of control trajectories on the model and picks the best. This is MPPI, model predictive path integral control. It optimizes for yield, energy, and throughput inside your limits.

Step 03

Fail safe to PID

On any fault the controller hands back to your existing PID in under 100 milliseconds. You hold the safety envelope the whole time.

Step 04

Improve on your data

Models retrain on your process history on-premises, with versioned rollback. Performance climbs without data ever leaving the plant.

Proof

Proven in chemical reactors

Continuous stirred-tank reactors are the class we have proven. We built a lab-scale CSTR and run the full control system on it, so the yield and energy numbers above come from real hardware, not from simulation.

Control is handed over in stages. The system runs in shadow and advisory first, so it never gets more autonomy than it has earned. Pilots are in progress with North American specialty chemical and pharmaceutical manufacturers.

See the deployment journey
Why it generalizes

One architecture, every unit operation

PID controls every process in every industry because it runs on one generic idea, an error signal. Acaysia works the same way. It runs on a generic description of a process, so a new unit operation is not a new project. You describe it the same way as a reactor, and the same controller runs it.

Every unit operation, described the same way
What has to balance Mass and energy, in and out
Where it connects Feeds, products, and utilities
What you measure Temperature, pressure, level
What you control Flows, valves, heating and cooling
Controller Reads the ontology. The same controller runs every unit operation.
Ontology One shared description for every unit operation.
CSTR Proven
Batch reactor In progress
Plug flow reactor In progress
Distillation column In progress
Crystallizer In progress
Evaporator In progress
More classes Roadmap

CSTR is proven on our own test reactor. The unit operations marked in progress have working surrogates. Each new one joins the same system. We do not rebuild the controller.

Safety and integration

Safe to put in a real plant

Acaysia sits next to your PLC and respects every interlock it already has. The safety architecture is unit-op-agnostic by construction. The same Trust Arbiter that supervises a reactor will supervise a column or a crystallizer.

Supervision

Trust Arbiter

Every control move is checked against your limits before it reaches the plant. Anything outside the envelope is blocked.

Fallback

PID under 100ms

On any fault the controller reverts to your proven PID in under 100 milliseconds. No gap in control.

Standards

ASIL-D inspired

The safety architecture is modeled on automotive ASIL-D and is SIL compatible. It never interferes with your Safety Instrumented Systems.

Integration

Brownfield drop-in

OPC UA and EtherNet/IP connect to the PLCs you already run. IEC 62443 cybersecurity considerations throughout. No rip and replace.

Works with the infrastructure you already have

SIEMENS ROCKWELL AUTOMATION Beckhoff Schneider Electric ABB OPC UA SIEMENS ROCKWELL AUTOMATION Beckhoff Schneider Electric ABB OPC UA

Take on a real process with us

We are taking on a small number of pilot partners through 2026 across chemicals, pharmaceuticals, and adjacent process industries. If you operate reactors, columns, or other continuous or batch unit operations and want to evaluate Acaysia on a real process, talk to us.

Book a discovery call