A Guide to Process Analytics in Industrial Plants
20 August 2025
Unlocking efficiency, compliance, and competitiveness through real-time gas and liquid monitoring.
Introduction
In an increasingly data-driven industrial landscape, the ability to see what’s happening inside your process lines in real time is no longer a luxury—it’s a strategic necessity. Process analytics offers exactly that: continuous, precise monitoring of gas and liquid streams to optimise operations, reduce waste, and ensure compliance.
This guide is for plant managers, operations directors, compliance officers, and decision-makers looking to understand not just what process analytics is, but how it can transform plant performance from the ground up.
What is Process Analytics?
Process analytics refers to the use of specialised instrumentation to monitor chemical and physical properties of gases and liquids directly within the process, as opposed to laboratory testing. These systems provide continuous data on critical parameters such as concentration, flow rate, pressure, temperature, pH, and chemical composition. Visit our dedicated webpage to find out more.
This data feeds into control systems, allowing for real-time adjustments that maintain optimal conditions, minimise waste, and ensure consistent output.
Why Process Analytics Matters
Process analytics is the backbone of modern process control. Here’s why:
- It delivers instant insight into what’s happening inside your plant
- It enables real-time corrective action
- It supports regulatory compliance and data traceability
- It feeds digital transformation initiatives, including automation, AI, and predictive maintenance
Business Benefits of Implementing Process Analytics
Real-Time Insight = Real-Time Control
No more waiting for lab results. Inline analytics shows you the exact state of your process as it happens, empowering quicker, smarter decision-making.
Key gains:
- Immediate deviation detection
- Faster resolution of quality issues
- Reduced product rejection
Increased Operational Efficiency
With real-time data, you can fine-tune input levels, optimise reactions, and avoid overuse of materials.
Key gains:
- Lower material and energy costs
- Improved throughput
- Less rework and downtime
Improved Product Quality
Tight process control means consistent output. Whether you’re producing chemicals, pharmaceuticals, or food, process analytics ensures you stay within spec.
Key gains:
- Uniform quality across batches
- Fewer customer complaints
- Higher brand trust
Predictive Maintenance & Asset Longevity
Analytics data can flag anomalies early, helping anticipate equipment wear or fouling before failure occurs.
Key gains:
- Fewer unplanned shutdowns
- Smarter maintenance schedules
- Extended equipment life
Simplified Regulatory Compliance
From emissions to effluent, compliance is easier when data is continuous, auditable, and automated.
Key gains:
- Easier reporting
- Stronger audit readiness
- Reduced risk of fines
Supports Sustainability & Digital Transformation
Process analytics underpins Industry 4.0 efforts and helps organisations meet environmental, social, and governance (ESG) goals.
Key gains:
- Lower emissions and waste
- Enhanced traceability
- Real-time KPIs for ESG reporting
Increased Profitability
All these benefits translate directly to the bottom line.
Key gains:
- Faster ROI
- Leaner, more agile operations
- Competitive advantage
Industries That Benefit Most
Chemical Manufacturing
VOCs, effluent control, and process yields are all improved with real-time analysis.
Pharmaceuticals
Ensure tight control over solvent recovery and contamination risks.
Food & Beverage
Improve water reuse, hygiene, and waste discharge compliance.
Oil & Gas
Monitor flare gases, vapour recovery, and water treatment in real time.
Pulp & Paper
Control fibre discharge and optimise heat and water recovery systems.
Mining & Metals
Monitor tailings and drainage for environmental and safety compliance.
Barriers to Adoption & How to Overcome Them
Cost Concerns: ROI is often faster than expected when efficiency gains and compliance savings are factored in.
Complexity: Modern systems are modular and designed for integration with existing control infrastructure.
Skill Gaps: Training and vendor support can bridge this, and analytics tools are becoming more user-friendly.
Resistance to Change: Position analytics as a tool for empowerment, not replacement.
Implementation Roadmap
- Assess Needs: Identify critical processes and compliance points
- Select Instruments: Choose analysers and sensors based on application
- Integrate with Controls: Link to SCADA/DCS/PLC systems
- Train Staff: Ensure operational teams understand the system
- Pilot & Scale: Start small, refine, then expand plant-wide
Common Misconceptions
“It’s only for emissions.” Incorrect. Process analytics improves quality, yield, and safety across all operations.
“We already have a lab.” Labs are essential, but they can’t deliver real-time data where it’s needed most: in the process.
“It’s too complex.” Not anymore. Modern systems are built for ease of use and integration.
Final Thoughts
Process analytics is more than a tool—it’s a mindset. A way of turning raw data into operational excellence. For forward-thinking plants, it represents one of the smartest investments they can make in the pursuit of efficiency, compliance, and competitive strength.
In a world where agility, sustainability, and data transparency are paramount, the question isn’t “can we afford to implement process analytics?” — it’s “can we afford not to?”
