Real-time AI control layer

Built for any process, in any plant

More yield from the plant you already have.

Acaysia is the real-time AI control layer for industrial processes: higher yield, lower energy, and a failsafe back to your PID in under 100 milliseconds.

Book a discovery call How it works
  • Key metrics Estimated yield and energy gains; results vary by customer
  • ~2% Yield improvement
  • ~10% Energy reduction
  • <100ms Failsafe response to PID

The problem

9 to 18 months per project, then drift

You’ve optimized this reactor before. You’ll do it again next year.

Only the highest-value plants ever got APC. The problem isn’t that optimization doesn’t exist. It’s that it doesn’t compose.

Each project rebuilds the same primitives. The model is bespoke. The controller doesn’t transfer. The improvement decays as the process drifts. Nine to eighteen months and several million dollars later, you have a slightly better version of what you started with, and the next reactor needs its own project from scratch.

A lot is being left on the table.

The controller

MPPI · model predictive path integral control

Optimization that reads the process

Acaysia describes your process as data, then optimizes against it in real time.

Schematic Faint lines: futures sampled from the model. Blue: the plan they weight toward, inside the lower and upper limits. White: what the process did.

How it works

Reactor · column · dryer

Process

The same four steps run whether the unit operation is a reactor, a column, or a dryer.

  1. Model the process

    Acaysia builds a model of your process from your plant data and known physics. That model is what the controller optimizes against.

  2. Optimize in real time

    Every cycle, the controller simulates thousands of control trajectories on the model and picks the best. This is MPPI, model predictive path integral control. It optimizes for yield, energy, and throughput inside your limits.

  3. Fail safe to PID

    On any fault the controller hands back to your existing PID in under 100 milliseconds. You hold the safety envelope the whole time.

  4. Improve on your data

    Models retrain on your process history on-premises, with versioned rollback. Performance climbs without data ever leaving the plant.

Real-time optimization

Intelligent, adaptive control

Control the Impossible

The controller re-plans every cycle against a model that keeps learning from your plant, so performance climbs instead of decaying as the process drifts.

Footage · settling tanks, top-down

Why it generalizes

One ontology, one controller

One architecture, every unit operation

PID controls every process in every industry because it runs on one generic idea, an error signal. Acaysia works the same way. It runs on a generic description of a process, so a new unit operation is not a new project. You describe it the same way as a reactor, and the same controller runs it.

Each new unit operation joins the same system. We do not rebuild the controller.

Every unit operation, described the same way
AspectExample
What has to balanceMass and energy, in and out
Where it connectsFeeds, products, and utilities
What you measureTemperature, pressure, level
What you controlFlows, valves, heating and cooling
Unit operation classes
  • CSTR
  • Batch reactor
  • Plug flow reactor
  • Distillation column
  • Crystallizer
  • Evaporator

AcaysiaDRT · spatial study

Your dryer, resolved before we touch a setpoint.

A DRT spatial study runs your own equipment’s geometry on a GPU. No plant data needed, nothing written to the plant.

Explore AcaysiaDRT

D3Q19 LBM · nL–100s L

Safety and integration

Next to your PLC, inside your interlocks

Safe to put in a real plant

Acaysia sits next to your PLC and respects every interlock it already has. The same Trust Arbiter that supervises a reactor will supervise a column or a crystallizer.

  1. 01 · Controller Acaysia Proposes the next move
  2. 02 · Supervision Trust Arbiter Checks it against your limits
  3. 03 · Execution Your PLC OPC UA · EtherNet/IP
  4. 04 · Process Your plant Every interlock respected

Outside your limits

Blocked before it reaches the plant

On any fault

Your PID takes over · < 100 ms

Schematic · the path of every control move Next to your PLC, not in place of it
  • ASIL-D inspired
  • SIL compatible
  • Never interferes with your Safety Instrumented Systems
  • IEC 62443 considerations throughout
  • No rip and replace

Works with the infrastructure you already have

A small number of pilot partners

Chemicals · pharmaceuticals · process industries

Take on a real process with us.

We are taking on a small number of pilot partners through 2026 across the process industries. If you operate reactors, columns, or other continuous or batch unit operations and want to evaluate Acaysia on a real process, talk to us.

Book a discovery call

Backed by

  • NVIDIA
  • a16z speedrun