The economics of running a plant have shifted: downtime has never been more expensive, sensors are everywhere but their data goes unused, and energy and CO₂ now decide which sites survive. At the same time the players who build a plant have never been more fragmented. That is the gap PlantPilot closes.
Unplanned downtime costs the world's largest industrial companies about 11% of revenue — an hour in a process plant runs into six figures. Predicting it is worth more than any spare-part discount.
A single offshore installation carries tens of thousands of data points, and less than 1% of that data reaches anyone who decides. Most plants record, few learn.
In energy-intensive industries, energy and feedstock are the largest cost blocks and CO₂ pricing adds to them. A 5–20% efficiency gap is the difference between a site that closes and one that expands.
OEM, EPC, engineering offices and service contractors each hold a piece of the plant. The purchase price is only 20–30% of an asset's lifetime cost — the other 70–80% is decided in operation, where nobody has the whole picture.
Sources: Siemens, The True Cost of Downtime 2024 · McKinsey, Why oil and gas companies must act on analytics · McKinsey, Analytics-driven maintenance · Deloitte, Aftermarket services · Cefic, Growth and competitiveness
One as-built twin, built from documentation that already exists, in which OEM, EPC, engineering partners and operator see the same plant — with the access each of them needs.
Click a part, request a re-engineering from the original engineering, get comparable vendor quotes with frame contracts applied — and order in the same flow.
Sensor and actuator data from every party flows into one hub. Pattern recognition learns how the plant behaves and tells you what will fail, when, and what to do about it.
Given your production target, PlantPilot computes the operating strategy with the lowest total cost of ownership — and reports energy, material and CO₂ per unit as a by-product.
Plants on one shared twin — from air separation to specialty chemicals
Spare-part cost saved for operators until now
Energy saved by running plants at their proven optimum
Digital twins exist. Data lakes exist. What does not exist is a system that connects the two across every company involved and turns them into an operating optimum — that is what the three layers of PlantPilot do.
Get a demo and an individual version of PlantPilot for your plant or your installed base — and see what one collaborative twin, one data hub and one TCO optimum are worth. Whether you build plants, engineer them or operate them: every partner in the chain wins on every level.
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