Wonderware Solutions for Chemical Production

Wonderware helps chemicals producers improve asset utilization, maintain consistent quality and keep costs in check, all while protecting people and the environment.

Raising yield and driving compliance for chemical production

The power and ease of use of Wonderware software enable more flexible and agile production, while also reducing unit costs, energy usage, greenhouse gas intensities and plant emissions.

    • Wonderware solutions support value creation and sustainability for chemical producers. Whether you produce organic specialty chemical, inorganic bulk chemicals, biofuel or fertilizers, Wonderware can help bring your operations into control and compliance. Our software augments your ability to improve plant and facilities operations continuously, safely and with less waste.

    • Wonderware solutions provide chemical producers with the focused operations measurements such as model-based, real-time measurement of Overall Equipment Effectiveness (OEE), energy and cost accounting.  Tracking such key performance indicators closely generates better insights for every value-generation step, all within a real-time business context.

    Wonderware solutions can deliver significant increases in the plant or facility's sales value of production (SVOP) and contribute to sustainability by easing the environmental, health and safety compliance concerns that are increasingly occupying the minds of business leaders in this sector. And as the IIoT evolves to offer new solutions for performance and compliance, we will be there to help you phase them into your business.

    Specialty Chemicals

    Supplying the chemical ingredient needs of industry

    Manufacturers of the specialty chemicals on which so many other manufacturers rely for the chemical agents, additives, flavorings and other ingredients of their end products, tend to be more market-driven than fine, petrochemical or pharmaceutical manufacturers. Their products are often central to their customers’ end solutions offerings so they need the agility to adapt operations to rapidly fluctuating global competition and market dynamics.

    Specialty chemicals producers must improve asset utilization continuously and maintain consistent quality while keeping operating costs in check. Market survival requires new levels of performance, predictability and cost effective regulatory compliance. And the faster they can vary their offerings or produce smaller lots to capitalize on emerging market opportunities, the greater will be the positive impact on both the bottom line and customer satisfaction.

    Wonderware bases its specialty chemicals software offerings on a digital real-time information-based management platform. It is designed to provide all plant functions, operational stakeholders and the extended supply chain with the right information at the right time.

    Wonderware software addresses these key specialty chemical production challenges:

    • Reduce waste
    • Increase yields
    • Improve profitability
    • Decrease variability in process performance
    • Increase capacity
    • Easier and faster data analysis and knowledge management
    • Improve workflow and collaboration
    • Reduce inventory (and need to stockpile)
    • Improve agility and response to operational variances

    Inorganic Chemicals

    Adding production value safely and with respect for the environment

    Profitable production of inorganic chemicals, such as titanium dioxide, chlor-alkali products and carbon black, requires a delicate blend of discrete, continuous and batch processing, integrating mechanical, chemical and electro-chemical processes. This requires the sophisticated understanding of control and automation for which Wonderware products are well known.

    Wonderware software helps address these key challenges for inorganic chemical production:

    • Reduce waste
    • Manage and maximize asset performance
    • Maximize repeatable operations
    • Monitor performance
    • Analyze and benchmark production data
    • Optimize energy consumption


    Reducing greenhouse gases

    Biofuel production can make a major contribution to environmental sustainability due to the fact that biofuels have a more favorable carbon balance than traditional fossil fuels, but the significant challenges must be overcome. Throughput, yield and reliability must be maximized in the face of dynamic production and market situations. With changing economic subsidies, competing oil-for-food and oil-for-biodiesel prices and unpredictable agricultural conditions, the challenges of maximizing throughput, yield and reliability are daunting. Wonderware software provides biofuel manufactures the measurement, connectivity and control capabilities they need to improve profitability, safety and compliance.

    Wonderware software addresses these key challenges:

    • Increase production throughput
    • Improve batch yields
    • Improve process efficiencies
    • Manage and maximize assets
    • Enforce disciplined operations
    • Analyze and benchmark production data

    Fertilizers - Ammonia and Urea

    Enriching agriculture

    As the world’s population increases, the demand for fertilizers is growing proportionately. Except for a few regions of the world, the cost of the natural gas feedstock for ammonia production is, and will continue to be, quite high. Maximizing the yield of ammonia and urea at minimum cost and operational risk is essential to the long-term competitive success of fertilizer companies striving to help farmers meet increasing demand for food across the globe. For decades, Wonderware has helped ammonia and urea producers around the world operate their plants safely, reliably, sustainably, cost-effectively and at peak levels of operational performance.

    Wonderware software addresses these key challenges:

    • Effectively managing the transformation of the workforce
    • Reducing energy consumption and cost
    • Improving process safety
    • Reducing greenhouse gas emissions

    Ascend is a global leader in the production of nylon, plastics and synthetic fibers

    Its products are found in thousands of commercial and industrial products, including carpet, tires and apparel, as well as agricultural products, animal feed and personal care products. Watch this success story and find out more.

    Solutions Overview

    Whether you need operations visibility; production and packaging operations management; compliance and quality improvement; asset performance management; or maintenance and uptime solutions; Wonderware has the broadest set of integrated software offerings for the chemicals industry.

    Operations Visibility Applications

    Compliance, Sustainability and Quality Applications

    Asset Performance and Maintenance Management Applications

    Chemical Production Solutions Defined

    Wonderware offers a complete range of industrial software solutions for specialty chemical production, including HMI and SCADA software, manufacturing operations and information management, asset management and maintenance.

    Wonderware SCADA

    Wonderware SCADA solutions provide situational awareness for plant personnel to make faster and more effective decisions, enabling them to implement corrective actions quickly, before problems or critical conditions occur.

    Wonderware MES, Recipe and Batch

    Wonderware MES, recipe and batch management solutions help process orders to specification. They automate recipe and batch execution, improving product yields and manufacturing capacity while reducing waste and product variability. 

    Electronic records of production execution, material flows and integrated quality management help eliminate paperwork and manual data collection, provide real-time performance information and reduce the cost of regulatory compliance. Enterprise integration capabilities provide supply chain visibility, better decision support for improved forecasting, planning,and scheduling as well as enabling swifter new product introductions.

    Wonderware Operations/Manufacturing Intelligence

    Wonderware operations and manufacturing intelligence solutions are the foundation for deeper plant intelligence. They bring real-time operational insight, analysis and reporting on key performance Indicators and monitoring of day-to-day processes.

    Asset Performance Management

    Asset performance management increases equipment utilization and return on assets (ROA) through by improving equipment inspection, condition monitoring and maintenance.

    System Maintenance

    Wonderware’s seasoned consultants, architects, project managers, engineers and system integration partners are uniquely qualified to provide design engineering and product application services for all aspects of supervisory control, operations and asset management in chemical production.