Best Advanced Process Control (APC) Systems
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Compare the Top Advanced Process Control (APC) Systems as of July 2025
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What are Advanced Process Control (APC) Systems?
Advanced Process Control (APC) systems are computer-based systems that use mathematical models and algorithms to optimize the performance of industrial processes. APC systems aim to maintain a steady state operation with tight control over process variables such as temperature, pressure, flow rate, and composition. It incorporates feedback from sensors in the process to monitor performance and take corrective action when needed, in order to keep the process operating in the desired range. APC systems can help improve efficiency, reduce energy usage, increase throughput, and reduce product variability. Compare and read user reviews of the best Advanced Process Control (APC) systems currently available using the table below. This list is updated regularly.
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Epicor Connected Process Control
Epicor Software
Epicor Connected Process Control (CPC), formerly eFlex Systems, provides manufacturers a flexible, no-code/low-code MES solution. No programming or special skills required. Digital work instructions, with multi-media capabilities, along with the ability to integrate virtually any device with communication capabilities, provides 100% historical record of the product and the process. Providing data insight, from production reports, to part history, quality summary and more — address issues quickly, minimize waste and disruptions. Whether you start small in subassembly areas, an entire line, or apply enterprise wide - we work with manufacturers of all sizes and needs. Hosted on prem or in the cloud, you decide what's best for your operations. -
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Model Predictive Control Toolbox
MathWorks
Model Predictive Control Toolbox™ provides functions, an app, Simulink® blocks, and reference examples for developing model predictive control (MPC). For linear problems, the toolbox supports the design of implicit, explicit, adaptive, and gain-scheduled MPC. For nonlinear problems, you can implement single- and multi-stage nonlinear MPC. The toolbox provides deployable optimization solvers and also enables you to use a custom solver. You can evaluate controller performance in MATLAB® and Simulink by running closed-loop simulations. For automated driving, you can also use the provided MISRA C®- and ISO 26262-compliant blocks and examples to quickly get started with lane keep assist, path planning, path following, and adaptive cruise control applications. Design implicit, gain-scheduled, and adaptive MPC controllers that solve a quadratic programming (QP) problem. Generate an explicit MPC controller from an implicit design. Use discrete control set MPC for mixed-integer QP problems.Starting Price: $1,180 per year -
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MPCPy
MPCPy
MPCPy is a Python package that facilitates the testing and implementation of occupant-integrated model predictive control (MPC) for building systems. The package focuses on the use of data-driven, simplified physical or statistical models to predict building performance and optimize control. Four main modules contain object classes to import data, interact with real or emulated systems, estimate and validate data-driven models, and optimize control input. While MPCPy provides an integration platform, it relies on free, open-source, third-party software packages for model implementation, simulators, parameter estimation algorithms, and optimization solvers. This includes Python packages for scripting and data manipulation as well as other more comprehensive software packages for specific purposes. In particular, modeling and optimization for physical systems currently rely on the Modelica language specification.Starting Price: Free -
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INCA MPC
Inca Tools
Advanced Process Control (APC) is a very cost-effective way to optimize your plant performance without changing the hardware. An APC application stabilizes the operation and optimizes production and/or energy consumption. A very valuable side effect also results in a better understanding of your production process. Advanced process control (APC) refers to a broad range of techniques and technologies that interact with the base layer process control systems (built up with PID controls). Some APC technologies are e.g. LQR, LQC, H_infinity, Neural, fuzzy, and MPC (Model-Based Predictive Control). An APC application optimizes your plant every minute, over and over again, 24 hours per day, 7 days per week. MPC is the most popular APC technology used in the industry. The Model Predictive Control software uses a model of the process to predict the behavior of the plant in the foreseeable future. Typically a couple of minutes to even several hours ahead. -
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PlantPAx
Rockwell Automation
Producers like you are adept at navigating the complexities and challenges of staying competitive. This is true in a variety of industries ranging from pharmaceuticals, consumer packaged goods, and food and beverage to mining and chemical. That’s why it’s so important to implement the latest technological advancements to continue your ever-evolving digital transformation journey. From the control room to the board room, process system users face the persistent challenges of balancing productivity against budget and resource constraints as well as proactively addressing evolving operational risks. Meet these challenges and experience real productivity gains in all areas of your plant with the PlantPAx distributed control system (DCS). System features positively impact the lifecycle of your plant operations by ensuring that plant-wide and scalable systems drive productivity, improve profitability, and reduce overall risks for operations. -
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Emerson DeltaV
Emerson
DeltaV S-series Electronic Marshalling with CHARMs lets you land field cabling wherever you want, regardless of signal type or control strategy. The DeltaV™ Distributed Control System (DCS) is an easy-to-use automation system that simplifies operational complexity and lowers project risk. The state-of-the-art suite of products and services increases plant performance with intelligent control that is easy to operate and maintain. The DeltaV DCS adapts to meet your needs, scaling easily without adding complexity. The inherent integration of the DeltaV system extends to batch, advanced control, change management, engineering tools, diagnostics, and more. -
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Pavilion8
Rockwell Automation
Complex industrial processes make it challenging to be both market-driven and sustain profitable operations. Manufacturers must adjust their production methodology to introduce a greater variety of higher-value products and shorter production runs. They need to produce more, run efficiently and improve product quality to the limits of available equipment. For this, they must ensure maximum uptime and more efficient transitions with less waste. In addition, manufacturers are facing stronger public demand to reduce their environmental impact and operate within regulated emissions limits. Rockwell Automation Pavilion8® Model Predictive Control (MPC) technology is an intelligence layer on top of automation systems that continuously drives the plant to achieve multiple business objectives—cost reductions, decreased emissions, consistent quality, and production increases—in real-time. -
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Aspen DMC3
Aspen Technology
Develop more accurate and sustainable APC models covering a wider operational range by combining linear and nonlinear variables with deep learning. Improve ROI with rapid controller deployment, continuous model improvement and simplified workflows to enable easier use by engineers. Revolutionize model building with AI and streamline controller tuning with step-by-step wizards to specify linear and nonlinear optimization objectives. Increase controller uptime by accessing, visualizing and analyzing real-time KPIs in the cloud. In today’s ever-evolving global economy, energy and chemical companies need to operate with newfound agility to meet market demand and maximize margins. Aspen DMC3 is a next-generation digital technology helping companies sustain a 2-5% improvement in throughput, a 3% increase in yield and 10% reduction in energy consumption. Learn more about next-generation advanced process control technology. -
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COLUMBO
PiControl Solutions
Closed-loop universal multivariable optimizer for Model Predictive Control (MPC) performance and Model Predictive Control (MPC) quality improvements. Use data in Excel files from DMC (Dynamic Matrix Control) from Aspen Tech, or from RMPCT (Robust Model Predictive Control Technology) from Honeywell, or Predict Pro from Emerson and use it to generate and improve correct models for the various MV-CV pairs. Amazing new optimization technology does not need step tests as required by Aspen tech, Honeywell, and others. It Works entirely in the time domain, is easy to use, compact, and practical. Model Predictive Controls (MPC) can have 10s or 100s of dynamic models. One or more could be wrong. Bad (wrong) Model Predictive Control (MPC) dynamic models produce a bias (model prediction error) between the predicted signal and the measured signal coming from the sensor. COLUMBO will help you to improve Model Predictive Control (MPC) models with either open-loop or completely closed-loop data. -
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AVEVA APC
AVEVA
AVEVA APC is model predictive advanced process control that improves your process economics. In today’s economic environment, manufacturers are faced with reduced capital budgets and overhead, rising manufacturing and energy costs, and intense global competition. Comprehensive Advanced Process Control from AVEVA, helps you address complex manufacturing challenges with state-of-the-art automatic control solutions that can extract maximum value from your processes. It can improve production yield and quality and reduce energy consumption. It can help you optimize manufacturing operations and make the performance improvements you need to improve your bottom line continuously. AVEVA APC is a comprehensive model predictive advanced process control software that improves process profitability by enhancing quality, increasing throughput, and reducing energy usage. It uses modern, state-of-the-art technology to provide automatic control systems that are capable of releasing process potential. -
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System 800xA is not only a DCS (Distributed Control System) it’s also an Electrical Control System, a Safety system, and a collaboration enabler with the capacity to improve engineering efficiency, operator performance, and asset utilization. With the built-in electrical control system, ABB Ability System 800xA provides ways to be in control of the complete electrical system, from high-voltage switchgear to low-voltage motor control. Whether together with 800xA DCS or not, ABB Ability System 800xA is the ideal solution as your Electrical Control System. Reduce hardwired cabling on switchgear by connecting to intelligent devices, no matter which standard protocol you have. The high reliability on digital communication improves the information flow from the devices and additional electrical measurement equipment can be removed.
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Apromon
PiControl Solutions
Apromon is an online software product for monitoring the PID loop control performance of primary and Advanced Process Control (APC) loops. Apromon evaluates single loops, cascade loops, any Advanced Process Control (APC) loops and even signals that have PV only but no controller associated with them. Apromon has the unique power to automatically convert flow controllers, pressure controllers, temperature controllers, level controllers, online analysis controllers, and any Advanced Process Control (APC) controller into a single “grade” factor, just like the grade given by a professor to a student on a test or an examination. 100 indicates the best performance and 0 indicates the worst. Runs automatically every set period so that performance is always being calculated and archived. Runs all the time, and does not skip any period for any tag like some competitor products. -
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Pitops
PiControl Solutions
Pitops is the only software product that performs truly closed-loop system identification with PID controllers in Auto mode or even of secondary PID controllers in a Cascade mode, without the need to break the cascade chain and to conduct additional time-consuming and intrusive plant step tests. No other competitor tool can do successful transfer function identification using data with PID controllers in Cascade mode (Pitops is the only one). Furthermore, Pitops performs transfer function identification entirely in the time domain whereas all other competitor tools use the more complicated Laplace (S) or Discrete (Z) domain. Pitops can even handle multiple inputs and identify multiple transfer functions simultaneously. Pitops performs multiple inputs closed-loop transfer function system identification in the time domain using a new proprietary breakthrough algorithm, far superior to the older methods like the ARX/ARMAX/Box and Jenkins methods that are used in competitor tools. -
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Guidewheel
Guidewheel
Get more from existing assets, lower costs, and set your team up to win with Guidewheel's AI-powered platform. The fastest way to improve factory operations. Accurately track downtime and root causes to improve utilization and efficiency. Forecast throughput and accurately track planned vs. actual production. Monitor OEE in real time and see how you’re trending over time. Accurately track cycles, cycle time, and performance against targets. Monitor energy usage and find opportunities to reduce consumption and cost. Learn of maintenance needs before they develop into issues. Monitor conditions like temperature, flow, humidity, and pressure. Reveal and address losses like preventable downtime, long changeovers, and late starts to unlock hidden capacity. Get AI-driven alerts the moment performance deviates from plan, so your team can take corrective action to stay on track. Build customer trust by delivering on time every time.Starting Price: $59 per month -
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Cybernetica CENIT
Cybernetica
Cybernetica delivers Nonlinear Model Predictive Control (NMPC) based on mechanistic models. Our software product, Cybernetica CENIT, offers a flexible architecture that can meet any industrial challenge with optimal solutions. Multivariable optimal control, predictive control, intelligent feed forward, optimal constraint handling. Adaptive control through state and parameter estimation, and feedback from indirect measurements through the process model. Nonlinear models are valid over larger operating ranges. Improved control of nonlinear processes. Less need for step-response experiments and improved state and parameter estimates. Control of batch and semi-batch processes, control of nonlinear processes operated under varying conditions. Optimal grade transition in continuous processes. Safe control of exothermal processes and control of unmeasured variables, such as conversion rates and product quality. Reduced energy consumption and carbon footprint.
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Advanced Process Control (APC) Guide
Advanced process control (APC) systems are computer-based systems used to monitor, analyze and optimize processes in industrial plants. They are used to improve the quality of a product/process, reduce costs, and increase throughput/load. APC systems help ensure that processes run smoothly, efficiently and with minimal waste.
APC systems typically consist of four main components: sensors, controllers, actuators and displays. Sensors measure variables such as temperature or pressure; controllers take those measurements and adjust the settings on the actuators; actuators make adjustments to the process parameters; and displays show real-time data about the process for operators to monitor.
Several different types of APC algorithms are available for controlling a given process. For example, model predictive control (MPC) uses mathematical models of a process to predict future behavior based on current conditions and calculations from past operations. This allows it to anticipate changes before they occur in order to make corrective actions quickly enough not just correct deficiencies but prevent them from occurring in the first place. Model predictive control can also be used when multiple variables must be considered simultaneously in order to maximize efficiency or minimize costs. Other types of algorithms include Proportional Integral Derivative Control (PID), Statistical Process Control (SPC), Cascade Control Loop (CCL) and Optimization by Simulation (OBS).
An important benefit of APC systems is their ability to modify set points automatically based on changing conditions or inputs from an operator’s interface so they react quickly without manual intervention. This can lead to improved consistency as well as more efficient use of resources since fewer adjustments need to be made by hand throughout the course of production runs. Also, since all data is logged within an APC system, it can easily be analyzed afterwards for further optimization opportunities using additional statistical analysis tools like regression modeling or data mining techniques if desired.
Overall, advanced process control systems offer a wide range of benefits when compared with traditional methods for monitoring industrial processes due to their accuracy, automated operation capabilities and analytical capabilities which allow for ongoing improvements even after initial installation is complete.
Advanced Process Control Software Features
- Modeling: Advanced process control (APC) systems provide the ability to model complex processes and create mathematical models of how they will perform under different conditions. This allows operators to better understand how their process works and gives them greater insight into potential problems that could arise.
- Predictive Control: APC systems include predictive control capabilities, which use algorithms and historical data to anticipate future process outcomes and make decisions to keep the system running in an optimal state. This reduces the need for manual adjustments and improves overall process performance.
- Optimization: APC systems can identify areas where processes can be tuned or adjusted for maximum efficiency or throughput, such as optimizing feed rates or increasing production yields. This helps reduce costs associated with wasted materials, energy, or labor resources.
- Fault Detection & Diagnostics: APC systems are equipped with fault detection algorithms that are able to detect anomalies in a process before they become catastrophic failures. It also includes diagnostics tools which help determine the root cause of problems so that corrective actions can be taken quickly and efficiently.
- Automation: APC systems are designed to automate certain tasks within a process in order to minimize human intervention, ensuring consistency in outputs and freeing up personnel for other activities. In addition, it provides safeguards against human errors by automatically adjusting parameters when necessary without requiring manual intervention from an operator.
Types of Advanced Process Control Software Systems
- Model-Based Advanced Process Control: This type of Advanced Process Control (APC) system uses mathematical models of the process to analyze data, develop control strategies, and automate the entire process. It can also be used to optimize product quality and performance.
- Multivariable Advanced Process Control: This type of APC uses multiple inputs from sensors throughout the system to monitor a process or its output in order to detect any potential problems or changes that may occur.
- Adaptive/Robust Advanced Process Control: These types of systems are designed to automatically adjust their parameters to changing conditions in the system in order to maintain optimum performance and productivity.
- Predictive Advanced Process Control: This type of APC uses forecasting algorithms and analytical models based on historical data examples to predict future states in order to anticipate problems before they become an issue.
- Optimization Based Advanced Process Control: This type of APC uses optimization algorithms that consider multiple objectives simultaneously with constraints like cost, safety, environmental impact, etc., in order to determine the best overall configuration for a given system.
- Self-Tuning Advanced Process Control: This type of APC uses algorithms to automatically configure control parameters on-the-fly without manual tuning or intervention.
- Real Time Optimization Advanced Process Control: This type of APC is used to optimize a process in real time using feedback from sensors and other data points, as well as optimization algorithms.
- Neural Network Advanced Process Control: This type of APC utilizes artificial neural networks to detect changes in the system and adjust parameters accordingly.
- Expert System Advanced Process Control: This type of APC uses expert systems and artificial intelligence to monitor a system or its output in order to detect any changes or potential risks. It then offers suggestions on how to address these issues.
Benefits of Advanced Process Control Software
- Increased Efficiency: APC systems can be used to help identify and optimize the most efficient process settings possible. This means that production processes can be optimized in real-time based on current conditions, leading to increased efficiency and faster turnaround times.
- Improved Product Quality: By monitoring and controlling process variables such as temperature, pressure, flow rates, etc., APC systems can help reduce variability in product quality by providing more consistent control of the process.
- Reduced Energy Consumption: Through accurate control of the temperature and other environmental parameters, energy use can be reduced both during production processes as well as during idle periods when machines are not in use.
- Reduced Waste Generation: With timely feedback from an APC system, operators can make sure that production processes are only running when they need to be and with no unnecessary waste or pollution being generated.
- Reduced Maintenance Costs: By having a detailed feedback loop between the machine’s sensor readings and its controller, wear-and-tear on parts can be minimized over time leading to fewer breakdowns and reduced repair costs.
- Improved Reliability: Advanced process control systems can help reduce downtime and improve machine reliability by providing more detailed information on the status of key components. This can lead to improved production uptime as well as higher quality levels in the long term.
Who Uses Advanced Process Control?
- Process Engineers: Responsible for setting up, configuring, and maintaining the APC system to ensure proper performance, typically used in engineering and manufacturing.
- Operators: Use the APC system to monitor and control process variables in real time in order to maintain optimal performance.
- Maintenance Technicians: Troubleshoot issues with the APC system, as well as provide regular maintenance and upgrades.
- Quality Control Specialists: Utilize data from an APC system to assess whether a product meets customer requirements.
- Plant Managers: Monitor production metrics (such as throughput) at a high level with an APC system.
- Data Scientists/Analysts: Leverage data from an APC system for predictive analytics and machine learning applications.
- Supply Chain Professionals: Use information from an APC system to maximize efficiency and predict demand fluctuations.
- Production Schedulers/Planners: Leverage current process data from an on-going basis with an APC system to plan ahead of potential changes or issues that may arise in production schedules.
- Corporate Executives/Decision Makers: Analyze real-time performance metrics captured by the APC systems in order to make informed decisions regarding long-term strategies or investments.
How Much Does Advanced Process Control Software Cost?
The cost of advanced process control (APC) systems can vary greatly depending on the type and complexity of the system. APC systems typically range from tens of thousands to hundreds of thousands of dollars, with more advanced and specialized systems costing even more. The exact cost will depend on factors such as the size and complexity of the system, any customization that is needed, hardware and software requirements, installation or implementation costs, and maintenance fees.
For small-scale applications, an APC system may cost anywhere from $20,000 to $50,000. A midsize setup could cost between $75,000 and $100,000 while a fully customized advanced APC system could reach upwards of half a million dollars or more. Additionally, many suppliers offer different kinds of payment plans or financing options which can help make the total cost more manageable.
It is important to note that although the upfront cost might seem high initially, an APC system can offer significant savings over time through improved process efficiency and enhanced product output quality. Ultimately, it’s important to weigh the benefits provided by an APC system against its associated costs in order to decide whether or not it’s worth investing in such a solution for your business needs.
What Integrates With Advanced Process Control Systems?
Advanced Process Control (APC) systems can integrate with a variety of different types of software. These include graphical modeling, economic modeling, numerical optimization, statistical process control (SPC), data collection, industrial automation, and reporting software. Graphical modeling software allows users to visually model and analyze the interactions between process variables and control loops. Economic modeling software allows users to calculate the costs associated with various production processes and make decisions based on economic considerations. Numerical optimization software enables operators to improve process performance by automatically adjusting parameters such as set points in response to changing conditions or objectives. SPC software helps identify potential quality issues by collecting, analyzing, and displaying data collected from process operations. Data collection software gathers information about production processes for use in advanced analysis tools like APC systems. Finally, reporting tools allow users to generate detailed reports summarizing the performance of their production processes over time.
Advanced Process Control Trends
- Decreased Cost: APC systems have become increasingly affordable, allowing more companies to take advantage of their numerous benefits.
- Increased Efficiency: APC systems are designed to optimize processes, resulting in improved productivity and cost savings.
- Improved Quality: By monitoring process conditions and automatically making adjustments to keep them within set limits, APC helps ensure consistent product quality.
- Enhanced Safety: Automated safety features such as automatic shutdowns help protect operators from hazardous conditions.
- Reduced Waste Generation: By minimizing human error and providing real-time feedback on process conditions, an APC system can reduce the amount of waste generated.
- Increased Availability and Scalability: Highly reliable components and sophisticated software allow for greater scalability. Additionally, modern APC systems are web-enabled for remote access or control by mobile devices.
- Easier Installation & Integration: Newer APC systems require less cabling and fewer field instrumentation points than older versions, making installation easier and faster. Furthermore, they are designed to integrate easily with other plant automation solutions such as SCADA (supervisory control and data acquisition).
- Increased Regulatory Compliance: By monitoring and controlling the process, APC systems can ensure that production is carried out within the regulations set by governing bodies.
How To Choose the Right Advanced Process Control System
- Identify the Process and Its Goals: The first step in selecting an advanced process control (APC) system is to determine what process it will be controlling, and also specify the overall goals of the APC system. For example, is it meant to improve efficiency and throughput, reduce emissions or waste, increase production quality standards? Once these goals are established, they can be used as a basis for selecting an appropriate APC system.
- Assess Available Technologies: After processes and goals have been determined, the next step is to assess available technologies that could fit into a given application. This evaluation usually involves analyzing existing systems’ performance objectives and considering any new technology solutions that might offer improvements in power consumption or other metrics. Additionally, existing infrastructure should be considered alongside potential new hardware investments.
- Compare Cost of Implementing Solutions: Once several potential solutions have been identified, it's important to compare the cost of implementing each solution using a life-cycle analysis that looks at both initial investment costs and long term operational savings associated with each solution over time.
- Choose the Appropriate Solution: After comparing different solutions on various criteria including cost comparative analysis, it's now time to choose which APC system best suits the needs of your application based on its functionality and performance capabilities - ensuring it meets all previously established goals from Step 1. It's important to analyze potential risks associated with each particular solution before making a final decision in order to ensure there are no surprises down the road when it comes time for implementation or adjustments later on down the line if needed for unforeseen circumstances or events Use the tools on this page to compare advanced process control software by user reviews, features, pricing, operating system, and more.