PiControl Solutions
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PiControl Solutions
PID / APC OptimizationMonitoring & DiagnosticsProcess SimulationOPC Communication
PID TuningAPC ImplementationMPC MaintenanceSystem IdentificationProcess Control DesignDCS/PLC Programming
PID100: PID Tuning Certification & Primary Process ControlAPC200: Industrial Advanced Process Control DesignAPC275: PLC/DCS-based APC ExamplesMON300: Process Control Diagnostics & Industrial StatisticsMPC700: Industrial Model Predictive ControlPID475: Batch Reactor ControlBLR217: Boiler Control LoopsDCS450: Function Blocks for APC ImplementationSTA200: System Identification – Time Domain ModelsSTA300: Advanced System Identification – Time Domain Models
DCS400: DCS Training for Control Room OperatorsPLC475: PLC Hardware, Programming & DesignOPC500: OPC Communications Theory & PracticalsSEC600: Process Control Software, Hardware & Cyber SecurityPLC480: SIEMENS TIA Portal TrainingDCS485: SIEMENS PCS7 TrainingDCS495: EMERSON DeltaV Training
PIP215: Process Instrumentation – PressurePIT115: Process Instrumentation – TemperatureCWT550: Control Wiring & Termination
IHE825: Industrial Heat ExchangersSTB835: Steam Trap BasicsSGB845: Sight Glass BasicsCBF127: Compressor, Blower & Fan Maintenance
PLT100: Industrial Process & Plant Safety
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PetrochemicalsSpecialty ChemicalsPharmaceuticalsPolymersAmmonia and UreaAlcoholAir Separation
ProductionRefiningLNG
Power GenerationRenewablesUtilities
CementBrickSteelGlass
AutomotiveRoboticsAircraft
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AI-based Process Control Software for
PID Tuning,
Optimization and Monitoring.

A comprehensive ecosystem integrating modern process control products, services, and training.

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Trusted worldwide — process control teams at 200+ plants trust PiControl.
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Products

Our AI-based process control technology

24 products across four categories — optimization, monitoring, simulation and OPC communication. Built on closed-loop system identification.

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Multi-objective PID tuning, DCS-based APC design, and MPC maintenance, powered by AI closed-loop multivariable stepless system identification. True process models, unmeasured disturbance rejection, no plant step tests.
View Optimization Software →
PITOPSClosed-loop multivariable SysID & PID/APC Optimization→SUPERTUNEOnline auto-adaptive stepless PID tuning→
AI-powered real-time monitoring of PID, APC, MPC, control valve, and sensor health, with automated root-cause diagnostics and actionable fix recommendations.
View Monitoring Software →
APROMONOnline AI-based process control performance monitoring (& diagnostics)→PiLoggerHigh-speed raw data logging & trending→
Real-time process and PID tuning simulators with built-in control systems and a full SCADA interface — everything on one computer. Perfect for universities, training centers, and industrial workforce development.
View Simulation Software →
SIMCETPID tuning simulator for training & certification→STYROSIMFull-scale polymer plant dynamic simulator→20+ UNITSDistillation, heat exchangers, reactors, pumps…→
Robust OPC connectivity for integrating control systems and plant historians, lab-sample management, realistic client-to-server data-flow simulation for training, testing, and validation.
View OPC Software →
PiBridgeDual OPC client bridge across networks→PiOPCServerSimulation OPC server with embedded PID loop→PiLimsOnline laboratory information management→
Services

From PID to MPC — complete process control expertise, delivered by professionals.

Two decades of field engagements — on-site or remote, worldwide. Each loop tuned to its real plant objective.

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SP

PID Tuning Consulting

10,000+ PID loops optimized across diverse PLC/DCS systems - delivering faster disturbance rejection, tighter control, and measurable plant performance gains.

ResultReduced variability by 50%+
+4%

APC Implementation

200+ APCs implemented within major DCS/PLC platforms - increasing production rates and delivering measurable utility-cost savings.

ResultAchieved 2–10% monetary benefits
NOW

MPC Maintenance

Enhanced AspenTech, Honeywell, Yokogawa, and many other MPC controllers entirely from closed-loop real data, no plant step test.

ResultImproved 50+ MPCs
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Training

Learn industrial process control from the best

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PID Tuning Training

Closed-loop system identification, multi-objective PID tuning, control loop design and diagnostics - the practical, control room perspective.

Hands-on withSIMCET, PITOPS

DCS & PLC Training

Practical exposure to Siemens, Emerson, Rockwell, Yokogawa, Honeywell — basic and advanced functionality, design and programming.

Hands-on withDCS/PLC tools

APC & MPC Training

From building complete APC solutions in PLC/DCS environments to knowing exactly when MPC is the right choice, this training equips you with the practical skills to boost throughput, reduce variability, and improve energy efficiency across your plant.

Hands-on withPITOPS, APROMON

Delivery

Classroom
Live in Houston, TX and Zagreb, Croatia — or at the customer location.
Live Online
Live virtual instruction with real-time interaction.
Self-Paced
Web-based video courses and software modules, on your own schedule.
AudienceCompanies & individuals
Next SessionHouston, TX — June 15–16, 2026
Industries

One platform, tuned for every industrial sector

Select an industry to see where PiControl's process control software runs today — from refining and petrochemicals to power, cement and pharmaceuticals.

All 16 industries
PiControl eliminates costly step tests and stabilizes reactors, distillation columns, and polymer lines under varying feed conditions. Plants report 2–4% yield increase, up to 50% variability reduction, and 2–5% lower energy use. The system ensures tighter temperature and composition control, cleaner data, and faster grade transitions, turning process stability directly into higher profitability.
Explore Chemical Applications →
Petrochemicals→Specialty Chemicals→Pharmaceuticals→Polymers→Ammonia & Urea→Alcohol→Air Separation→
In upstream, refining, and LNG operations, PiControl tackles multivariable instability and feed composition swings that cause off-spec production and shutdowns. Its adaptive APC algorithms deliver 3–6% throughput gain, fewer compressor trips, and up to 8% energy savings. Operators achieve steadier separation, distillation, and liquefaction performance, maximizing uptime and product recovery.
Optimize Oil & Gas Control →
Production→Refining→LNG→
Power plants and renewables face fluctuating loads and combustion dynamics. PiControl's adaptive PID and closed-loop identification reduce boiler oscillations by 40%, improve load response by 20%, and cut fuel consumption by 3–5%. Utilities gain smoother turbine control, faster grid balancing, and more reliable generation, translating directly to lower operating costs and higher efficiency.
Explore Energy Solutions →
Power Generation→Renewables→Utilities→
Cement kilns, steel furnaces, and glass lines demand precise thermal control. PiControl minimizes temperature drift, fuel waste, and off-spec batches, achieving 2–4% energy reduction and up to 30% fewer shutdowns. Its AI-based tuning keeps kilns, meltflows, and casting loops stable, ensuring uniform product quality and stronger process economics across heavy industry operations.
Enhance Process Stability →
Cement→Brick→Steel→Glass→
Manufacturing lines rely on exact motion and thermal control. PiControl fine-tunes robotic arms, conveyors, and curing systems for up to 25% faster cycle times, 15% fewer rejects, and 10% lower utility demand. By isolating unmeasured disturbances and optimizing PID loops, it delivers smoother automation, precise positioning, and consistent quality across automotive, aerospace, and robotics production.
Improve Automation Control →
Automotive→Robotics→Aircraft→
The PiControl difference

Why engineers choose PiControl process control software

The core differentiator · Normal operating data

AI-based Closed-Loop Stepless SysID

Multivariable AI-based dynamic model identification directly from closed-loop data — no step tests or plant disruption, while detecting and isolating unmeasured disturbances.

Understand our SysID
Real plant objectives, not textbook loops

Multi-Objective PID Tuning

AI-driven PID tuning that targets real plant objectives — rejecting disturbances, optimizing complex controllers, and ensuring stable performance despite nonlinearities or valve issues.

See how it works
Beyond traditional MPC

Disturbance-Rejection, Modular and Adaptive APC

Delivers superior control performance by managing nonlinear behavior and unmeasured disturbances far more effectively than traditional MPC solutions.

Discover our APC approach
Integrated vendor · One methodology

All-In-One: Software + Consulting + Training

Powered by decades of hands-on industrial expertise, we offer a complete end-to-end solution: proven software, expert consulting, and extensive training programs — all delivered by one reliable partner.

Explore our ecosystem
Trusted by Industry Leaders

Award-winning results, in our customers' words

EXCELLENCE
AWARD

Process Control Excellence Award — Issued by the Industrial Automation Forum.

For two decades of measurable APC and MPC results across refining, petrochemicals, and power.

“
PITOPS gave us models we trusted in two days. The MPC stability we got after re-tuning was worth the engagement on day one.
Process Control Lead
Global refining major · Texas
We cut loop variability by more than half across the unit without a single plant step test. The closed-loop identification simply works.
APC Engineer
Petrochemical complex · Gulf Coast
SUPERTUNE keeps our compressor loops on target around the clock. We stopped chasing tuning drift after every grade change.
Lead Instrument Engineer
Polymer producer · Europe
The PID tuning training changed how our whole team thinks about control — practical, mathematical, and immediately usable on the floor.
Reliability Manager
Power generation · Southeast US
COLUMBO let us deploy full MPC on the existing Siemens controller — no new platform, no new license headache. Remarkable.
Automation Director
Air separation plant · Middle East
APROMON found three loops silently costing us throughput that nobody had flagged in a walkdown. The root-cause diagnostics pointed straight at the valve.
Process Engineer
Cement plant · Southeast Asia
Our whole DCS team went through the PID100 course together. Six months later, tuning is a shared language instead of one engineer's guesswork.
Control Room Supervisor
Specialty chemicals · Midwest US
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FAQ

Quick answers to the questions we hear most

The short version. For the deep dive, our guides go all the way down to the math.

Ask an engineer
Modern process control software improves stability and efficiency by identifying how a process actually behaves, then using that data to automatically tune control loops, eliminate oscillations, and catch performance drift before it costs you money. Tools like PITOPS perform system identification to build accurate process models for PID/APC optimization and design, SUPERTUNE automatically diagnoses and corrects sluggish or oscillating loops online without manual trial-and-error, and APROMON continuously monitors control performance in real time so gains aren't lost over time. Together, this means fewer oscillations, tighter operation near operation and safety constraints, smoother handling of grade transitions, and measurable, sustained gains in efficiency, throughput, and profit.
Traditional system identification methods often fail in industrial plants because they depend on many open-loop step tests that are often time consuming, require process stability, force controllers out of AUTO, disrupt production, and introduce safety risks. These methods also assume linear, disturbance-free behavior — conditions that rarely exist in real operating environments. Studies show that 60–80% of PID loops in industry run sub-optimally due to existence of disturbances, valve issues, and poor model accuracy. PiControl's AI-based closed-loop system identification eliminates these challenges by identifying true process dynamics by isolating and rejecting unmeasured disturbances and identifying valve issues directly from closed-loop plant data, without new step tests or production interruptions. This approach delivers accurate models, robust tuning, faster deployment and reliable controller performance under real plant conditions. See our system identification guide for details.
Yes, PiControl software integrates seamlessly with any DCS or PLC system using standard OPC-DA and OPC-UA communication. Our technology has been thoroughly tested with major industrial platforms, including Honeywell Experion, Emerson DeltaV, Yokogawa CENTUM VP, ABB Ability Symphony Plus, Siemens PCS 7, Rockwell PlantPAx, Schneider EcoStruxure, and many others. No proprietary hardware, custom gateways, or vendor-specific interfaces are required. This ensures fast deployment, reliable data exchange, and full compatibility with both modern and legacy control systems across all industrial sectors.
Traditional PID tuning methods do not work well the moment you leave a simple step test tuning - not good for complex setpoint changes, disturbance dominant processes and valve issues. In contrast our PID tuning crushes all these limitations with fast, gain-dominant, no-overshoot tuning that handles every loop challenge with precision.
Request a free short software demo meeting, where our engineers walk you through the PiControl tools that best match your plant's needs. They will demonstrate PITOPS as a multivariable closed-loop stepless system-identification and multi-objective PID/APC tuning platform, SIMCET as a real-time process control training and tuning simulator, and APROMON as a continuous control-loop monitoring and diagnostics technology. If you provide process data, we can run the identification and modeling steps directly on your plant's real dynamics, giving you a precise preview of controller performance, stability, and expected improvements.
Browse all guides →
Partner with PiControl

Three ways to begin with PiControl

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Two engineers reviewing PiControl software on a tablet

From plant data to action

Process simulation, loop tuning, or performance monitoring. Join a short software demo using your own plant data.

Schedule demo
PiControl consultant reviewing a control project with plant engineers

Bring us your toughest problem

Challenging PID loop performance, deteriorating MPC, and badly designed APC logic. Our process control engineers will support you immediately and resolve the issue remotely or on-site.

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Engineer in a live online PiControl training session

Get certified in process control

Live classroom in Houston, Zagreb, or on-site at your plant, online, or self-paced. Pick the format that fits you or your team.