Most plants don't have a process problem — they have a control problem. We turn PID loops into managed assets with continuous monitoring, automated health scoring and fault detection, so the plant runs closer to design intent.
Studies consistently show the majority of PID loops in operating plants are not performing as intended. The control layer — the foundation of everything — is quietly broken, and it costs money every minute of every shift.
60–80% of loops are poorly tuned, running in manual, or oscillating. Operators bypass automation, adding human variability and workload to every shift.
Uncontrolled variability hides in throughput figures, recovery rates, energy and reagent consumption, and equipment wear — compounding silently, every minute.
Every rotating asset has a maintenance schedule; every instrument has a calibration plan. Yet loops are commissioned once, never revisited, with no scoring, no prioritisation, no systematic review.
“No stable PID → no optimisation → no value. APC starts with PID discipline. You can't optimise noise.”Why control discipline comes first
Full visibility. Continuous monitoring. Automated intelligence — the same rigour applied to any critical piece of plant equipment.
Every loop tracked in real time — no manual audits, no gaps in visibility across the control layer.
Each loop receives an objective health score, enabling prioritisation of the highest-impact problems first.
Automatically identifies oscillation, dead time, poor tuning, valve stiction and loops running in manual.
Prioritise the worst performers, fix high-impact constraints first, and shift loops from Manual → Auto → Optimised.
Advanced control works as intended when the base layer is stable and disciplined — instead of fighting noise or being switched off.
Performance data reflects true plant capability — not noise masquerading as signal.
When control is reliable, operators engage with automation rather than overriding it.
Every digitalisation initiative — from IIoT to AI analytics — depends on a controlled, stable process.
Small fixes, massive impact. Control the loops — control the plant.
Benchmark basis: industry studies consistently find 60–80% of PID loops in one of three failure states (poorly tuned, manual, oscillating); value ranges reflect Talonite loop-remediation outcomes on operating plants.
Delivered through the Talonite Three Horizons journey — Foundation → Optimise → Improve — with ROI tracked, validated and compounded through our Smart Eye value layer. Every solution, every discipline.
See how we deliver value →We begin by identifying your highest-value loop opportunities, prioritising targeted improvements, and delivering measurable outcomes. Let us show you your plant's control performance in real terms — objectively scored, ranked by impact.
Continuous, automated monitoring of every PID loop in the plant — health scoring, oscillation and fault detection — so control loops are managed as performance assets rather than set-and-forgotten.
Valves wear, processes drift and tuning ages. Without monitoring, a large share of loops end up oscillating, saturated or in manual — quietly injecting variability into the process that operators then fight downstream.
Reduced variability — typically 5–15% — across critical circuits. A stable plant runs closer to design intent, and stable loops are the precondition for advanced process control to deliver its full value.
A rapid loop assessment quantifies where control is breaking down and which loops to fix first for maximum operational gain.