Optimizing Conductive Polymer Production with TrendMiner at Heraeus Epurio

Get to know Heraeus Epurio

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Heraeus Group, a global technology leader, focuses on delivering solutions for electronics, environmental, health, and industrial applications. Heraeus Epurio, one of its subsidiaries, specializes in specialty chemicals, including Clevios®, a pioneering conductive polymer for electronics like capacitors, displays, and smart textiles.

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With its origins as a family pharmacy founded in 1660 in Hanau, Germany, Heraeus is one of the top 10 family-owned German companies. It boasts over $30 billion in annual revenue and operates with 17,200 employees across 40 countries.

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Challenges

• Solving production issues was time-consuming and inefficient.
• Manual and untimely batch data analysis.
• Difficulties in incorporating third-party data into analyses.
• Lacked the capabilities to reduce operational costs and enhance efficiency.

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Outcomes

• Empowered decision-making through easy and fast data access.
• Prevented 2-3 batch failures annually, saving raw materials and time.
• Reduced rework rates and operational costs.
• Conducted Root Cause Analysis (RCA) to uncover key process parameter relationships.
• Created a “Golden Fingerprint” batch as a benchmark for process excellence.
• Achieved operational efficiency and reduced unplanned downtime.

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Solutions

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TrendMiner Industrial Analytics Platform

Heraeus Epurio implemented TrendMiner’s platform to overcome operational challenges and drive efficiency.

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“At Heraeus Epurio, user-friendly dashboards provide us with industrial analytics that boost efficiency and performance. With root cause analysis and fingerprinting, we are saving production batches that would otherwise have failed.”

Thomas Geub, Global Head of Automation and Data Science, Heraeus Epurio

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Data Analytics for Operational Excellence

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The growing market for conductive polymers has heightened the need for precision in Heraeus Epurio’s production processes. Deviations could compromise product quality and affect profitability.

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With the AVEVA PI System already in place, Heraeus sought a tool to overcome its data comparison and correlation challenges. Enter TrendMiner, enabling comprehensive, user-friendly batch data analysis.

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Some Use Case Examples

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• Golden Batch Fingerprint: Improved quality stability by monitoring deviations in critical parameters.

• Optimized Filtration: Enhanced filter replacement schedules, extending operational lifetime.

• Safety Valve Dimensioning: Validated under-dimensioned safety valves to ensure optimal reactor performance.

• Cooling System Monitoring: Prevented cooling failures through real-time brine temperature monitoring.

• Pump Maintenance: Leveraged predictive alerts for pump conditions, reducing downtime.

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The Road Ahead

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Currently, Heraeus Epurio actively uses TrendMiner, with plans to expand via the SaaS package on AWS. The next steps involve incorporating machine learning algorithms for anomaly detection and prescriptive diagnostics, transforming operational capabilities across all levels.

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“By eliminating lost batches and monitoring energy-intensive assets, we’re cutting costs while achieving genuine operational excellence.”

Sören Hams, Data Engineer, Heraeus Epurio

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Meet the Product Behind the Hero

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TrendMiner’s advanced analytics software enables engineers and operators to analyze, monitor, and predict production outcomes. Whether on-premises or in the cloud, its intuitive platform empowers teams to make smarter, data-driven decisions at scale.

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Request a Free Demo to see how TrendMiner can drive success for your business.

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