Advanced Process Control

Ready to increase throughput and stability?

Stabilize Operations. Unlock Hidden Capacity.

Operational stability is critical, but increasingly difficult to maintain. Feedstock variability, constrained equipment, workforce turnover, and aging control strategies all introduce risk and limit performance.

Advanced Process Control (APC) helps industrial operations reduce variability, operate closer to constraints, and maintain stable performance under changing conditions. Spartan Controls delivers APC programs that not only improve performance, but are designed to be sustained over time.

What We Deliver

A Sustainable Approach to Advanced Process Control

Spartan helps customers move beyond one‑time APC projects toward long‑term operational stability and performance improvement.

Our approach combines process expertise, control systems experience, and operational context to ensure APC applications remain effective and trusted by operations teams.

Start with an APC Opportunity Study
Leverage our library of industry solutions
Sustain results with an APC program.

Our APC services focus on:

Why Spartan Controls?

Proven Results

Metals – Grinding Circuit APC

Unlocking $30M per Year by Stabilizing a Grinding Circuit Bottleneck

A gold mining operation struggling with grinding circuit instability and frequent SAG mill overloads turned to advanced process control to break through a major production bottleneck. By coordinating crushers, mills, and cyclones as a single optimized system, SpartanPRO™ Grinding Circuit APC stabilized mill loading, reduced operator intervention, and enabled consistently higher throughput despite a highly variable ore body. The result was an 8% increase in net throughput, worth $30M per year, along with a dramatic reduction in overload events and process variability.

Read the Full Grinding Circuit APC Success Story

Potash – Hot Thickener APC

Recovering $2.5M Per Year by Optimizing Hot Thickener Operation

In a potash operation where limited process visibility forced conservative thickener operation, enabled operators to safely run closer to true process limits. Using model predictive control to manage slow dynamics and multiple constraints, the solution increased underflow solids, reduced tailings flow, and significantly cut product losses to saturated brine. These improvements translated into per year in recovered value while reducing equipment stress and operating risk.
Read the Full Story

Pulp & Paper – Bleach Plant APC

Cutting Bleaching Costs by $2.5M Per Year with APC

Facing rising chemical costs and inconsistent bleach plant performance, a kraft pulp mill implemented APC to optimize reagent usage across bleaching stages. By automatically coordinating chemical addition based on pulp flow, kappa, and brightness targets, the mill reduced variability, improved brightness control, and significantly lowered bleaching costs. The APC solution has delivered per year in chemical savings while reducing operator workload and improving day‑to‑day consistency.

Read the full bleach plant APC story