Four stages from a first conversation to a system the plant relies on. The second one — a feasibility study on real samples — exists so that the capital decision is made with evidence rather than optimism.
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The sequence is the same whether the answer turns out to be an analyser, a different measurement point, or a process change that needs no instrument at all.
About an hour, online or on site. Where the losses come from, which deviations hurt, what a bad batch costs, and which measurement points would actually change a decision. No instrument has been chosen at this stage.
Real process material, measured, modelled, and compared against the reference method. The report states what is measurable, at what uncertainty, and what it would take. It stays with you whether or not anything is ordered.
Measurement configuration, points, integration design, and a payback calculation built on the plant's own cost of waste, rework and downtime. Sometimes the honest recommendation is a process change rather than an instrument.
Installation, model calibration on production data, validation, operator training, and continued model development as the process evolves. Model updates are covered for the first twelve months under the agreement.
A measurement that stops at a screen in a cabinet changes nothing. The result has to arrive in the layer where the plant already makes decisions.
No sample line, no conditioning skid, nothing to consume. The probe sits in the reactor loop or the pipeline and looks at the process itself.
Model inference, pass/fail classification, deviation alarms, and an audit trail of which model version produced which number. Everything is written to a local database on the plant's own hardware.
The result appears where operators and control loops already look, over PROFIBUS, PROFINET or Modbus. That is the difference between an instrument that reports and an instrument that participates.
Spectrally does not only measure — it helps to steer. Robert Stachurski, CEO · PIPC
Values flow on to MES, SCADA or LIMS as release documentation and compliance evidence. When the network is unavailable, measurement and logging keep running locally and synchronise afterwards.
Specification and price are properties of the platform — quote them anywhere. Payback, savings and reduction percentages are properties of a segment and an installation. Resin economics are not water economics, and we will not pretend otherwise on a sales call.
How much more the global instrument houses ask for a comparable process-analytics installation. The capital range above is the whole reason a mid-size chemical plant can consider inline Raman at all.
| Segment | Payback | Savings | Other measured effects |
|---|---|---|---|
| Resins — continuous chemistry | 6–10 months | +EUR 180 000 / year | OEE improvement, batch repeatability |
| Resins — European producer, 6-month observation | not measured | — | losses −10 %, waste −12 %, variability <1.5 % |
| Cosmetics — emulsions | not measured | +EUR 100 000 / year | mixing time −12 %, rework −8 % |
| Cosmetics — incoming quality control | not measured | qualitative | pass/fail in minutes, sampling delay removed |
| Water and wastewater | 18–24 months | — | ppm accuracy; first Polish water deployment |
| Nitrogen fertilisers — UAN / DEF (illustrative) | est. 8–14 months | — | off-spec −50–60 % (est.), DEF first-pass ~95 % (est.) |
| Specialty fertilisers — ATS (illustrative) | est. 8–14 months | — | off-spec −45–55 % (est.), QC workload −30–40 % (est.) |
| Silicones (illustrative) | not measured | — | off-spec −6–9 % (est.), reactor time −5–7 % (est.) |
The shortest path from “we think this might be measurable” to a documented answer.
Then that is what the report says. The platform includes SERS for analytes below plain Raman's sensitivity and NIR where Raman bands are weak — and there is a separate, technology-neutral audit of a plant's analytical quality-control system, priced as a fixed fee, whose recommendation is sometimes a process change and no new instrument at all.
An hour on your process comes first. Everything after that — feasibility, architecture, payback — follows from what that hour finds.