SECTOR-SPECIFIC SOLUTIONS

Chemical

In the chemical industry, even the smallest deviation in parameters can cause a batch to fail to meet target quality criteria, leading to significant cost losses. For companies producing paint, adhesives, and construction chemicals, profitability rests on manufacturing the correct formulation under the right process conditions, and achieving it First Time Right (FTR).

At Corius, we digitally transform your complex chemical production processes end-to-end, and use our AI-powered models to optimize critical production parameters (temperature, pressure, mixing speed, and more) in real-time. We increase your FTR and FPY rates while maximizing your formula security and process standardization.

We are here to accelerate your transition to a data-driven manufacturing culture and minimize cost losses.

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AI Solutions for the Chemical Industry, Paint, and Adhesive Production

First Time Right (FTR) Production and Formula Optimization

The chemical sector's largest cost item is products that fall out of spec and require rework. Our artificial intelligence algorithms analyze historical production data to simulate the necessary parameters for the correct viscosity, color, and density before production begins. This increases your First Pass Yield (FPY) rates.

Dynamic formula management and automatic dosing based on raw material variations.
Significant increase in FTR (First Time Right) rates and elimination of rework costs.
Real-time optimization of production parameters with artificial intelligence.
Integration of laboratory results with production site data.

End-to-End Traceability and Lot Management

Which raw material was used in which batch? Which supplier's product caused the quality issue? Retrospective traceability is vital for products like paint and adhesives. With our custom traceability software, we digitally record every step from raw material input to the shipment of the final product.

100% Lot/Batch traceability from raw material to final product.
Creation of Digital Product Passports and electronic Certificates of Analysis (CoA).
Smart barcode/RFID systems preventing the use of incorrect raw materials.
Ability to reach the root cause of customer complaints in seconds.

Predictive Maintenance for Critical Equipment

A mixer motor burning out or a pump stopping mid-process can cause tons of semi-finished product to solidify and turn into waste. By analyzing sensor data from your reactors, mixers, and filling lines, we preemptively warn of potential failures, preventing production delays and product loss.

Prevention of unexpected downtime in reactors, mixers, and filling machines.
Prevention of major cost losses due to product solidification or spoilage.
24/7 monitoring of equipment health through vibration and temperature analysis.
Integration of maintenance planning with the production schedule.

Secure Stock and Shelf Life Management

The shelf life and storage conditions of chemical raw materials are critical. We develop smart warehouse management systems that operate on the FEFO (First Expired, First Out) principle and recognize hazardous material classes (ADR). Eliminate quality risks arising from improper storage or the use of expired raw materials.

Prevention of raw material waste (scrap) through shelf life tracking.
Intelligent placement of hazardous and potentially reactive materials.
Ensuring production continuity through automatic order triggering.
Digital stock tracking compliant with legal regulations.

The Formula for Digital Transformation in the Process Industry

Full Control from Formulation to Filling

In chemical production, quality is hidden in the details. A 1-degree difference in reactor temperature or a deviation in mixing time compromises the product's structure. With our Process Control Systems (PCS) and AI models, we instantly monitor the field application of your Bills of Materials (BOM), minimizing operator discretion.

Dynamic Formula Management:Managing product variations and revisions from a single center, sending formulas to machines automatically.
AI-Powered Quality Prediction:Predicting whether the resulting product will pass quality tests (FPY) by analyzing process data before production is even finished.
Digital Work Orders and Weighing Control:Guiding operators with digital screens and preventing incorrect mixtures through precise weighing integration.
Energy and Consumption Tracking:Calculating the true product cost by tracking steam, electricity, and water consumption on a batch basis.

How Can We Improve Your Processes?

Breaking Down the Walls Between Lab and Production

Delays in sampling, testing, and approval processes slow down production. With our Laboratory Information Management Systems (LIMS) integrations, we ensure test results flow instantly to production, automatically alerting the line in out-of-spec situations. Quality becomes a part of the process, not just a control point.

LIMS Integration:Automatically retrieving data from lab devices (spectrophotometers, viscometers, etc.) and matching it with the production batch without manual entry.
Electronic Quality Approval:Giving automatic 'Proceed' or 'Stop' approval to the filling line based on test results.
Trend Analysis and SPC:Monitoring deviations in quality parameters (e.g., pH, density) as trends and intervening before they go out of limits.
Automatic Certificate of Analysis (CoA) Generation:Automatically generating analysis certificates for the customer from the system, eliminating human error.

Digitize Your Quality Processes

Protect Your Critical Equipment

In chemical plants, pumps, valves, mixers, and heat exchangers are the heart of the operation. Unexpected failures in this equipment can lead not only to downtime but also to hazardous situations. We monitor equipment health with IoT sensors, detecting signs of failure months in advance.

Mixer and Motor Health Monitoring:Detecting wear and tear in motors and reducers through vibration and current analysis.
Pump Cavitation Detection:Using artificial intelligence to detect situations where pumps are operating inefficiently or entering cavitation.
Heat Exchanger Fouling Monitoring:Optimally determining the cleaning time of heat exchangers by monitoring heat transfer efficiency.
Leak and Sealing Detection:Analyzing pressure data to detect potential leaks in pipelines early.

Predictive Maintenance Solutions

Ensure Full Compliance with Regulations

Regulations like SEVESO, REACH, and KKDIK are a reality of the chemical sector. We build digital infrastructures that make your production and storage processes 100% compliant with these regulations. Access all necessary reports for audits with a single click.

Digital Traceability Reporting:Instantly presenting all retrospective production records in the format auditors require.
Occupational Health and Safety (OHS) Software:Digitally managing near-miss incidents, risk analyses, and training on the field.
Waste Management Tracking:Recording the disposal processes of production waste in accordance with legal regulations.
MSDS Management:Ensuring Material Safety Data Sheets are current and accessible.

Let’s Simplify Your Compliance Processes

Frequently Asked Questions for the Chemical Sector

Will our existing formulas and recipes be safe?

Absolutely. From the first stage of the project, we initiate a security readiness process where we guide you on how to anonymize and encrypt your sensitive data. Our goal is to ensure that none of the information you provide will reveal actual formula details, thus fully securing it.

Even when all data is encrypted using methods defined by you, the infrastructure we set up is completely closed to unauthorized user access. Strict access controls are applied according to roles and permissions, and only authorized personnel determined by you can access formula details.

Furthermore, our entire collaboration process is governed by a mutual NDA (Non-Disclosure Agreement). This ensures your data privacy is fully protected both technically and legally.

In short, whether your formulas are at a lab scale or industrial scale, we maximize the security of your intellectual property with anonymized data processing, multi-layered encryption, access isolation, and NDA assurance.

Can we prevent color or viscosity deviations in production? Yes, this is one of our main goals. Our artificial intelligence models, which learn from your historical production data (raw material specs, ambient temperature, process time, etc.), predict potential deviations during production and warn the operator. This increases your FTR (First Time Right) rates.

Can your systems integrate with laboratory equipment? Yes. We can retrieve data from laboratory devices such as spectrophotometers, rheometers, and density meters directly into the software we develop, without manual entry. This eliminates human error and instantly matches analysis results with the production batch.

Do you have solutions suitable for Batch production? Our solutions are entirely designed according to Batch production dynamics. A separate cost, quality control, and traceability code are created for each batch. The system also optimizes the cleaning, downtime, and preparation times associated with discontinuous production processes.

We are a small-scale paint manufacturer, is this investment suitable for us? Certainly. Thanks to our scalable structure, you can start with only your most critical line or laboratory processes. We perform a 'Productivity Analysis' to identify the point where you will achieve the fastest Return on Investment (ROI) and structure the project accordingly.

Your Technology Partner Who Understands Your Chemistry

At Corius, we understand the sensitivities of the chemical sector; the importance of a mixture's viscosity, a pigment's tone, or a reactor's temperature. We don't just offer you software; we provide integrated solutions that optimize your production processes, combining process engineering and data science.

Process-Oriented Approach

Instead of standard manufacturing software, we develop process-oriented algorithms tailored to the nature of chemical processes (mixing, reaction, settling/curing).

Zero Defect Vision (FTR)

In your high-waste-cost sector, we target First Time Right production with a 'quality while producing' vision, rather than 'control after production'.

Regulatory and Safety Compliance

While developing our software, we focus not only on efficiency but also on safety standards and legal requirements such as SEVESO and OHS.