List of the Top 7 Advanced Process Control (APC) Systems for Windows in 2025

Epicor Connected Process Control offers an intuitive software solution designed to create and manage digital work instructions while maintaining strict process control, effectively minimizing the chances of errors in operations. By integrating IoT devices, it captures comprehensive time studies and detailed process data, including images, at the task level, providing unprecedented real-time visibility and quality oversight. The eFlex system is versatile enough to accommodate countless product variations and thousands of components, catering to both component-based and model-based manufacturers alike. Furthermore, work instructions seamlessly connect to the Bill of Materials, guaranteeing that products are assembled correctly every time, even when modifications occur during production. This advanced system intelligently adapts to variations in models and components, ensuring that only the relevant work instructions for the current build at the station are presented, enhancing efficiency and accuracy throughout the manufacturing process. In this way, Epicor empowers manufacturers to maintain high standards of quality control while adapting to the dynamic nature of production demands.

The Model Predictive Control Toolbox™ provides an extensive array of functions, an easy-to-use app, Simulink® blocks, and useful reference examples to streamline the development of model predictive control (MPC) systems. It effectively addresses linear problems by allowing the development of implicit, explicit, adaptive, and gain-scheduled MPC approaches. For more intricate nonlinear situations, users can implement both single-stage and multi-stage nonlinear MPC. Moreover, this toolbox comes equipped with deployable optimization solvers and allows for the incorporation of custom solvers as needed. Users can evaluate the performance of their controllers through closed-loop simulations within MATLAB® and Simulink environments. In the context of automated driving, the toolbox offers blocks and examples that comply with MISRA C® and ISO 26262 standards, which facilitates the rapid start of projects related to lane keeping assistance, path planning, path following, and adaptive cruise control. It enables the design of implicit, gain-scheduled, and adaptive MPC controllers that can solve quadratic programming (QP) problems while also facilitating the generation of explicit MPC controllers based on implicit designs. Furthermore, the toolbox accommodates discrete control set MPC for addressing mixed-integer QP challenges, thus expanding its versatility for various control systems. With its rich set of features, the toolbox guarantees that both beginners and seasoned professionals can successfully apply advanced control strategies in their projects. This versatility ensures that users across multiple domains can find relevant applications for their specific needs.

Advanced Process Control (APC) serves as an effective means to boost your plant's operational efficiency without necessitating any changes to hardware. By deploying an APC application, you can achieve stable operations while optimizing either production output or energy consumption, which in turn grants valuable insights into your manufacturing workflows. This concept includes a diverse set of methodologies and technologies that enhance basic process control systems, which are mainly built upon PID controllers. For instance, technologies associated with APC feature LQR, LQC, H_infinity, neural networks, fuzzy logic, and Model-Based Predictive Control (MPC). An APC application works tirelessly to optimize plant performance every minute of every day, ensuring that operational efficiency remains consistent. Among these different techniques, MPC is particularly prominent in the industry because it employs a process model to anticipate the plant's performance in the near term, usually from a few minutes to several hours ahead, thereby offering a tactical edge in operational management. By continuously refining processes, APC not only enhances immediate efficiency but also plays a crucial role in achieving long-term sustainability objectives, making it an essential component of modern industrial practices. The integration of these advanced strategies can lead to significant improvements in both productivity and environmental impact.

Pitops emerges as the exclusive software solution that can perform authentic closed-loop system identification with PID controllers in Auto mode or with secondary PID controllers in Cascade mode, all without the need to disrupt the cascade chain or engage in additional, time-consuming plant step tests. This positions Pitops as unmatched in the market, as no other competing software can accurately identify transfer functions using data gleaned from PID controllers operating in Cascade mode. Moreover, Pitops carries out transfer function identification purely in the time domain, setting it apart from other tools that depend on the more complex Laplace (S) or Discrete (Z) domains. The software is also equipped with an extraordinary ability to handle multiple inputs and simultaneously identify various transfer functions. By employing a cutting-edge proprietary algorithm, Pitops enables closed-loop transfer function system identification in the time domain with multiple inputs, vastly outpacing traditional techniques such as ARX/ARMAX/Box and Jenkins that are utilized by rival tools. This innovative methodology not only simplifies the identification process but also significantly improves both accuracy and efficiency, solidifying Pitops as the industry's premier choice. As a result, users can expect a more streamlined and effective approach to system identification that enhances overall performance.

Cybernetica is dedicated to delivering Nonlinear Model Predictive Control (NMPC) by leveraging mechanistic models. Our cutting-edge software, Cybernetica CENIT, boasts a flexible architecture designed to tackle a wide array of industrial challenges while producing optimal control strategies. This encompasses sophisticated multivariable optimal control, predictive control techniques, and smart feed-forward methods, all while adeptly managing various constraints. Additionally, our adaptive control features utilize state and parameter estimation, allowing for the integration of feedback derived from indirect measurements through the process model. Employing nonlinear models facilitates effective performance across broad operational ranges, significantly improving the management of complex nonlinear processes. Consequently, this approach reduces the dependence on step-response experiments and enhances the precision of state and parameter estimations. Moreover, we provide tailored control solutions for both batch and semi-batch operations, efficiently overseeing nonlinear processes that endure varying conditions. Our technology also guarantees optimal transitions in product grades during continuous operations, ensures the safe management of exothermic reactions, and controls unmeasured variables such as conversion rates and product quality. Ultimately, these advancements lead to decreased energy consumption and a minimized carbon footprint, while simultaneously boosting overall process efficiency. In conclusion, Cybernetica is fully committed to pioneering industrial control solutions that not only enhance performance but also promote sustainability in various sectors. Our relentless pursuit of innovation positions us as leaders in the field, enabling us to adapt to the evolving needs of our clients.

AVEVA APC is an innovative model predictive control system aimed at improving the economic performance of manufacturing operations. As businesses navigate a challenging economic environment marked by reduced budgets, rising energy costs, and intense global competition, AVEVA’s Advanced Process Control solutions address complex manufacturing challenges. These solutions employ advanced automatic control technologies that enhance the value generated by production activities. Not only does this system increase production efficiency and quality, but it also lowers energy usage. Additionally, it is instrumental in refining manufacturing processes, supporting continuous improvements that have a substantial positive impact on financial performance. By utilizing leading-edge technology, AVEVA APC offers a comprehensive strategy for process control, which ultimately fosters greater profitability through better quality, increased output, and lower energy costs. Therefore, for any manufacturer striving for success in a competitive landscape, AVEVA APC proves to be a vital asset that unlocks the full potential of their operations. Its implementation can lead to transformative results that define industry leadership.

Apromon is an innovative web-based software tool that specializes in assessing the efficacy of PID loop controls for both standard and Advanced Process Control (APC) systems. It provides evaluations for individual loops as well as cascade setups, diverse APC loops, and signals that do not have an associated controller but still feature a process variable (PV). A notable highlight of Apromon is its capability to convert various controller types—including those managing flow, pressure, temperature, and level—into a single "grade" factor, similar to how educators score students, where a score of 100 indicates peak performance and a score of 0 represents the lowest. The software is designed to operate continuously, conducting evaluations at predefined intervals to guarantee that performance metrics are accurately calculated and saved. In contrast to some other software solutions, Apromon ensures that every tag is monitored without exception, establishing itself as a dependable option for ongoing performance evaluation. This commitment to thorough monitoring not only fosters optimal control over processes but also empowers users with real-time insights to enhance their operational efficiency consistently. As a result, Apromon stands out in the industry for its reliability and comprehensive approach to performance tracking.