Optimization
Process control optimization software performs multivariable closed-loop system identification, PID controller tuning, automatic PID auto-tuning, and APC strategy design.
- PITOPS
- SUPERTUNE
- COLUMBO
Products
Process Control Software — PID Tuning, Advanced Process Control, Monitoring & Simulation Software for Industrial Plants
Process control software is industrial optimization software that improves the performance of PID controllers, advanced process control (APC) strategies, and control loop monitoring in manufacturing plants. PiControl Solutions develops process control software for closed-loop system identification, PID tuning optimization, automatic PID auto-tuning, MPC model identification, and real-time loop monitoring — all operating in the time domain and connecting to any DCS or PLC via OPC.
Most plants already run a DCS, PLC, or SCADA system. The performance problem is not the control system itself — it is that 60–80% of PID loops are poorly tuned, MPC models degrade silently, and oscillations cost money every day until someone tunes them out. Across 16+ industrial sectors and 40+ countries, engineers use PiControl process optimization software to reduce variability by 30–70%, recover 5–15% in energy losses on affected control loops, increase throughput on constrained units, and typically pay back the software cost within 3–6 months.
Our Process Control Software
Monitoring & Diagnostics
Process control monitoring software tracks PID and APC loop performance in real time, detects oscillations, diagnoses sticking valves, and ranks loops by economic loss across hundreds of loops.
- APROMON
- PiLogger
- PiLims
Simulation
Process control simulation software replicates real plant dynamics on a computer for PID tuning practice, operator training, and control strategy testing. Sixteen products including a real-time PID simulator and 14 unit-operation simulators.
- SIMCET
- STYROSIM
- PiDistill
OPC Communication
OPC communication software bridges process control software to any DCS or PLC using OPC-DA and OPC-UA protocols. Transparent connectivity between separated control systems.
- PiBridge
- PiOPCServer
01 · Optimization
Optimization
Multivariable closed-loop system identification, PID tuning optimization, automatic online auto-tuning, and closed-loop MPC model identification — three products covering the full optimization workflow from offline modeling to continuous online adaptation.
PITOPS
Multivariable closed-loop system identification and PID tuning optimization software. Identifies SISO and MIMO transfer functions for up to 50 inputs × 50 outputs from normal closed-loop operating data in the time domain — no bump tests required. Used to optimize PID tuning and design APC strategies on any DCS or PLC.
Learn MoreSUPERTUNE
Automatic online PID auto-tuning software that recalculates controller parameters every 1–5 minutes based on real-time process dynamics. Once configured, SUPERTUNE runs continuously inside the DCS or PLC environment, adapting tuning to fouling, catalyst aging, and feed quality drift — with no manual intervention.
Learn MoreCOLUMBO
Closed-loop MPC model identification software that extracts accurate multivariable transfer functions from existing model predictive control data — without removing the MPC from automatic mode. Used to refresh degraded MPC models and support MPC maintenance programs where re-stepping the unit is operationally unacceptable.
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02 · Monitoring & Diagnostics
Monitoring & Diagnostics
Real-time PID and APC loop performance tracking. Detect oscillations, diagnose sticking valves, log sub-second trends, and correlate offline lab analyses with online process data — across hundreds of loops simultaneously.
APROMON
Online control loop monitoring software. APROMON tracks PID and APC performance, detects oscillations, identifies sticking valves, and diagnoses tuning degradation in real time. Computes performance indices across hundreds of loops simultaneously and ranks loops by economic loss — turning loop maintenance into a prioritized program.
Learn MorePiLogger
High-speed industrial data logging software. PiLogger captures process variable, setpoint, and controller output trends at sub-second resolution for tuning analysis, post-mortem investigation, and root-cause troubleshooting. Connects to any DCS or PLC historian via OPC.
Learn MorePiLims
Laboratory information management system (LIMS) for process plants. PiLims captures lab analyses, tracks sample chains, and correlates lab results to real-time process data — bridging the gap between offline quality measurements and online control loop performance.
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03 · Simulation
Simulation
Real-time PID tuning simulator, a full styrene-plant DCS simulator, and 14 unit-operation simulators covering distillation, reactors, heat exchange, pumping, and more — used for PID tuning practice, operator training, and control strategy validation.
SIMCET
Real-time PID tuning simulator. Replicates the feel of tuning loops on a real DCS, with 20+ pre-built simulations covering flow, temperature, pressure, level, and composition loops, plus a testing & grading module used for PID tuning certification.
Learn MoreSTYROSIM
Styrene monomer plant DCS simulator. Full plant-scale dynamic simulator with PCS 7 control-room interface for operator training, alarm response practice, upset-condition rehearsal, and APC strategy validation.
Learn MorePiDistill
Continuous distillation column dynamic simulator. Captures full column dynamics including tray hydraulics, reboiler and condenser response, and feed composition disturbances — used for control strategy design, operator training, and engineering practice.
Learn MorePiDistill-B
Batch distillation column simulator. Models batch separation including reflux drum behavior, cut transitions, and end-point determination — ideal for training operators on the specific challenges of batch distillation in specialty chemicals and pharma plants.
Learn MorePiDistill-B Lite
Azeotropic batch distillation column simulator. Lighter-footprint version focused on azeotropic separations and entrainer-based distillation — used for training and engineering practice on non-ideal vapor-liquid equilibrium systems.
Learn MorePiAbsorption
Absorption column simulator. Models gas-liquid absorption dynamics for amine systems, scrubbing operations, and acid-gas removal — capturing column hydraulics, mass transfer behavior, and the impact of solvent regeneration on absorber performance.
Learn MorePiReact-T
Tubular reactor simulator. Models plug-flow reactor dynamics for cracking, polymerization, and other tubular reaction systems — including temperature profiles, conversion dynamics, and the interaction between feed rate, temperature, and residence time.
Learn MorePiReact-CSTR Coming Soon
Continuously stirred tank reactor simulator. Will model CSTR dynamics including residence time distribution, heat removal limitations, and exothermic reaction stability — critical for training on runaway-reaction prevention and CSTR temperature control strategies.
Learn MorePiFlow
Flow controller in heat exchanger simulator. Captures flow-loop dynamics with realistic valve characteristics, pump curves, and pressure-flow interactions — used to teach the fast-loop dynamics that dominate flow control behavior.
Learn MorePiLevel
Level controller in vertical tank simulator. Models tank level dynamics including process disturbances, integrating-process behavior, and cascade level-flow control — the classic case study for understanding integrating processes and override control.
Learn MorePiTemp
Temperature controller for heat exchangers simulator. Captures heat exchanger thermal dynamics with realistic dead time and time constants — used to teach the dead-time-dominated dynamics that make temperature control harder than flow or pressure control.
Learn MorePiTemp Plus Coming Soon
Closed-loop heat transfer simulator. Will be an advanced thermal simulation with cascade temperature control, secondary-loop dynamics, and disturbance rejection — extending PiTemp into multi-loop heat-transfer training scenarios.
Learn MorePiHEx
Heat exchanger network simulator. Models multi-unit heat exchanger networks with cross-coupling between hot and cold streams — used to teach the interaction effects that emerge in pinch-designed heat-integration networks.
Learn MorePiDeltaP
Pressure drop simulator. Captures pressure-drop dynamics across piping systems, control valves, and process equipment — used to teach the relationship between flow rate, valve position, and downstream pressure that drives valve sizing and selection.
Learn MorePiPump
Pump system simulator. Models centrifugal and positive-displacement pump dynamics with realistic curves and cavitation behavior — used to teach pump operating-point selection, control strategies, and pump-piping interaction.
Learn MorePiAgitator
Agitation effect simulator. Models mixing dynamics in stirred vessels including mixing time, blend uniformity, and impeller-driven flow patterns — used to teach the role of agitation in batch reactor performance, blending, and heat-transfer enhancement.
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04 · OPC Communication
OPC Communication
Connect any two OPC servers across different networks, protocols, or sites — and generate test data for development and demonstrations. Compatible with OPC-DA and OPC-UA.
PiBridge
OPC communication bridge software. A dual OPC client bridge connecting two OPC servers across different networks, protocols, or sites — used to enable transparent data exchange between separated control systems without proprietary middleware. Compatible with OPC-DA and OPC-UA.
Learn MorePiOPCServer
Simulation OPC server with embedded real-time PID control loop. PiOPCServer generates test data and validates OPC client connectivity for development, integration testing, and PiControl software demonstrations — providing a known-good OPC endpoint without requiring access to a live DCS.
Learn More
The PiControl Difference
Why engineers choose PiControl process control software.
Most industrial control loops underperform because the methods used to tune them are slow, disruptive, or vendor-locked. PID controllers account for 95%+ of all loops, and 60–80% of them are poorly tuned at any time. PiControl solves this in four specific ways.
01
Closed-Loop System Identification
PiControl extracts process models from 4–24 hours of normal closed-loop operating data — no bump tests, no open-loop step changes, no production disruption.
Learn How It Works
02
Time-Domain Modeling
All PiControl software performs system identification in the time domain, not the frequency domain — capturing dead time, nonlinearities, and multivariable interactions that frequency-domain methods routinely miss.
Read The Guide
03
DCS / PLC Agnostic
Compatible with every major DCS and PLC via OPC-DA and OPC-UA — Honeywell Experion, Emerson DeltaV, Yokogawa CENTUM VP, ABB Ability, Siemens PCS 7, Rockwell PlantPAx, Schneider EcoStruxure. No vendor lock-in.
See Compatibility
04
Software + Consulting + Training
The only independent vendor offering optimization, monitoring, and simulation software alongside expert consulting services and 30+ training courses — all built on the same closed-loop, time-domain methodology.
Explore The Ecosystem
Industries
Process Control Software for Every Industrial Sector
PiControl process control software optimizes industrial process control systems across refining, petrochemical, LNG, power generation, pharmaceutical, cement, and 10+ additional manufacturing sectors. Each industry runs different DCS or PLC platforms — but the closed-loop, time-domain methodology stays constant across all of them.
Trust
Trusted by process engineers worldwide
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Top 10 Oil and Gas Solutions Providers, 2023
— Energy Tech Review
FAQ
Frequently Asked Questions About Process Control Software
Process control software is industrial optimization software that improves the performance of PID controllers, advanced process control (APC) strategies, and control loop monitoring systems in process manufacturing plants. It includes tools for closed-loop system identification, PID tuning optimization, automatic PID auto-tuning, MPC model identification, and real-time loop performance monitoring.
Process control software falls into four main categories: PID tuning and optimization software (PITOPS, SUPERTUNE, COLUMBO), process control monitoring software (APROMON, PiLogger), process control simulation software (SIMCET plus 20+ unit operation simulators), and OPC communication software (PiBridge). Each category serves a different stage of the control optimization workflow.
PiControl process control software connects to DCS and PLC systems through OPC-DA and OPC-UA communication protocols. Compatible platforms include Honeywell Experion, Emerson DeltaV, Yokogawa CENTUM VP, ABB Ability Symphony Plus, Siemens PCS 7, Rockwell PlantPAx, and Schneider EcoStruxure. No proprietary hardware or middleware is required.
A process control system is the hardware-and-software environment that runs the plant — typically a DCS (Distributed Control System), PLC (Programmable Logic Controller), or SCADA package supplied by vendors such as Honeywell, Emerson, or Siemens. Process control software is the optimization layer that operates on top of that system to improve PID tuning, APC performance, and loop monitoring. PiControl develops the optimization software; it does not manufacture the underlying control system.
Process control software pricing depends on the product, the number of loops or variables licensed, deployment scope (single site vs. enterprise), and licensing term (annual vs. perpetual). PITOPS, SUPERTUNE, COLUMBO, SIMCET, and APROMON are licensed separately and bundled discounts are available. Request a software demo for current pricing and a tailored license proposal.
Automation software and SCADA execute control — they run PID loops, manage alarms, and display real-time process data. Process control software optimizes that execution — it identifies process models, calculates optimal tuning parameters, monitors controller performance, and designs advanced process control strategies. PiControl operates at the optimization layer above the DCS, PLC, and SCADA layer.
A typical PITOPS or COLUMBO deployment takes 1–2 days for installation and OPC connection setup, then 4–24 hours of operating data per loop for closed-loop identification. SUPERTUNE auto-tuning becomes active within hours of configuration. Plant-wide engagements covering 50–500 loops typically run 4–12 weeks when combined with PID tuning consulting or APC implementation services.
Request a free software demo and a PiControl engineer will run PITOPS, SUPERTUNE, COLUMBO, SIMCET, or APROMON against a process relevant to your plant — using your own historian data or a comparable simulation. Demos are delivered remotely via OPC connection or on-site for larger engagements.
Get started
Get started with PiControl process control software.
PiControl process control software is available worldwide — 40+ countries served and every major DCS or PLC supported via OPC. Choose the path that matches where you are today.