Yield Intelligence
Theoretical vs actual yield, tracked every batch — so loss stops being invisible.
Without theoretical-vs-actual tracking, yield loss quietly becomes an accepted cost and the baseline drifts down every quarter. PlantIQ tracks the gap batch by batch and maps it to the reason — RM lot, process parameters, operator inputs, equipment state.
Yield loss treated as normal is the most expensive habit in the plant
A plant that has run at 88% for three years believes 88% is the ceiling. It usually isn't. When variance is never measured against a theoretical baseline, the best batches are treated as luck and the worst as noise, and the average slowly sinks. PlantIQ makes the theoretical yield the reference line on every batch, so the gap is a number somebody owns rather than a cost everybody absorbs.
The factory constant: your baseline, not an industry average
Pure stoichiometric yield is the starting point, but no real reactor hits it. As batches accumulate, PlantIQ derives your plant's own operating baseline — the realistic best-case built from your strongest historical batches — and measures every new batch against that. You are benchmarked against your own best work, not a generic industry figure that doesn't fit your process.
Loss mapped to cause
A 4% shortfall is useless information; a 4% shortfall traced to Lot C-0892 from a specific supplier, on the morning shift, at an out-of-spec reactor inlet temperature is a decision. PlantIQ correlates yield against the variables that moved, so the conversation shifts from 'yield was down' to 'here is exactly what cost us the output.'
Frequently asked
How does theoretical vs actual yield tracking work?
PlantIQ sets the stoichiometric (theoretical) yield as a baseline, then measures each batch's actual yield against it and against your plant's own rolling best-batch baseline, mapping any gap to RM lot, process parameters and equipment state.
What is a factory constant?
It is the realistic operating baseline PlantIQ derives from your best historical batches once enough data accumulates — replacing pure theory as the reference line for judging every new batch.
Is my process data kept private?
Yes. Your batch data is strictly scoped to your plant. PlantIQ never mixes it with other customers' data and treats process data as a trade secret.
See your plant's true profitability
30-day structured pilot on your process, your batches, your baseline. No disruption. If PlantIQ doesn't show measurable yield or compliance value, we walk away.
Book a free operational audit