Sustainable Manufacturing: Modeling and Optimization Approaches to PID-Controlled Processes

This talk explores the critical role of PID control loops—the most widely used control technology in manufacturing and a major influencer of energy consumption and operational efficiency. Attendees will gain insight into the current state of PID tuning in industry and how suboptimal control affects sustainability goals. The session will introduce proven methodologies for developing accurate process models, calculating optimized tuning parameters, and applying standardized approaches for sustained loop performance. Emphasis will be placed on strategies that align with corporate sustainability initiatives, such as reducing energy waste, improving process stability, and increasing overall control effectiveness (OCE). Key Takeaways: The impact of poorly tuned PID loops on energy use and emissions Methods for data-driven process modeling and controller tuning Practical steps for embedding performance benchmarking into operational routines Ideal Audience: Automation and Process Engineers Sustainability Officers and Energy Managers Operations Leaders focused on Efficiency