Capture expertise.Optimize execution.

OptiStudio optimizes how your plant runs. ExpertFlow AI captures the expertise behind it, turning operational knowledge into traceable, continuously improving execution.

20 min: First operational draft
↓15%: Energy optimization potential
6 sites: Standardized operations
100%: Traceable decisions

Industrial plant operator in hard hat and high-visibility vest at an outdoor worksite — 6:42 AM · A plant in central Europe

The reality on the floor

Max walks in at 7 a.m. Years of operational knowledge walk in with him.

It's 6 a.m. at an industrial plant somewhere in central Europe. The first sun rays scatter through the roof glass. Reject rates are starting to creep up.

Max will pull up the procedure binder, realize section 4 was last revised in 2019, ignore it, and rely on what he remembers from the last time this happened. He's been doing this for twelve years.

Most of what he knows isn't written down anywhere. The official SOP is a 47-page PDF nobody has read end-to-end. The real SOP lives in his head and in the heads of three other people on shift.

The colleague who truly understood the drying procedure retired in February. He took twenty years of nuance with him.

This is the gap. Not training. Not documentation. A knowledge-capture gap and it's the one INSUS products were built to close.

Why this matters now

Most plants run on muscle memorynot operational intelligence.

Procedures were documented years ago. Reality changes every shift. Over time, expertise, execution, and operational standards drift apart.

The binder is outdated

Procedures live in static PDFs. Real execution lives with the operators running the line every day.

Expertise walks out

Critical operational knowledge leaves when experienced operators retire, transfer, or move sites.

Sites can't standardize

Plants are expected to run the same way, but every site follows different workflows and operational know-how.

Our products

Two products.One source of truth.

Most plants still rely on tribal knowledge, disconnected systems, and operational habits that never scale across shifts or sites. OptiStudio and ExpertFlow AI turn that expertise into connected, continuously improving operations.

Energy & process optimization

OptiStudio

The operational intelligence layer for your plant. It models asset behavior, connects to DCS and historians, and recommends setpoints that cut energy and CO₂ without hurting throughput.

Connects DCS, SCADA, historians, MES, and energy data
Builds hybrid AI and physics models per asset
Optimizes cost, kWh, and CO₂ per ton together
Tests what-if scenarios before operational rollout
Surfaces setpoint guidance with rationale and guardrails

Explore OptiStudio

Expert knowledge capture

ExpertFlow AI

The operational knowledge layer for your plant. It captures expert workflows, structures know-how into SOPs and rules, and delivers traceable guidance across every shift and site.

Searches regulations, SOPs, manuals, and plant standards
Runs guided expert interviews for industrial workflows
Captures objectives, constraints, and decision rules
Routes expert review with traceable edit history
Links every output to an approved operational source

Explore ExpertFlow AI

The journey

Six steps. Twenty minutes.One procedure that lasts.

Max sits down once. ExpertFlow AI structures everything he knows into a living SOP his whole team can search, use, and hand off.

Step 01
Sit down for the interview
ExpertFlow AI has already researched local regulations and standards. The conversation is guided twenty focused minutes, not a form to fill out.
Step 02
Review the draft
See what ExpertFlow AI captured objectives, constraints, decision rules, and failure modes laid out clearly for a quick expert check.
Step 03
Edit what's wrong
Correct what's wrong in your own words. Every edit is logged with a reason, and the system learns for the next interview.
Step 04
Approve and publish
Publish the SOP as your team's versioned, searchable reference with the audit trail compliance teams expect.
Step 05
Refine over time
When the floor changes, the SOP changes with it. ExpertFlow AI flags gaps, contradictions, and stale sections automatically.
Step 06
Hand it off
New engineers get the real procedure — not a dusty PDF. Onboarding moves from months to weeks, with answers on demand.

Who it's for

Max's the main character.He's not alone.

INSUS products give every role in industrial operations a version of the truth they can actually use.

Process engineers

Capture decisions and decision rules in minutes, not weeks. Stop being the only person who knows.

Plant managers

Procedures that are real, not theatrical. See what each shift actually does and where they diverge.

Operations leaders

Make every site operate like the best-performing site. Compare, benchmark, and standardize across plants.

Quality & training

SOPs that are current, traceable, and defensible. Audit-ready by design, not after the fact.

What's inside

An expert documentation colleague,always at your service.

Every capability is built so an industrial reviewer can trust it explainable, traceable, and contestable from the first day.

Autonomous researcher

Pulls local regulations, industry standards, and common practices across thousands of documents before the interview starts.

Guided AI interview

A conversation experts tolerate pre-filled context, smart follow-ups, and clear structure that turns talk into a structured draft.

Structured SOP capture

Objectives, constraints, decision rules, and failure modes explicit, named, and ready for review not prose operational artifacts.

Expert review workflow

Accept, edit, or reject with a reason. Every decision becomes signal for the next draft and a record for compliance.

Versioning & history

SOPs evolve without losing history. Compare versions across shifts and sites. Roll back when needed. Audit-ready by design.

Full explainability

Every claim traces back to who said what and when. Every recommendation explains itself. Industrial trust isn't optional it's the default.

Industries served

Built for the floor.Proven across industries.

Same intelligence layer, different vocabulary. INSUS products adapt to the regulations, workflows, and rhythms of each sector without asking your team to change how they work.

Pharmaceutical manufacturing environment

Pharma & biotech

GMP-grade procedures, captured fast

Validation-ready SOPs with every change traceable to the operator, the reason, and the source.

Metals & heavy industry

Standard work across hot lines

Capture the operator know-how that keeps cast and roll lines tuned before the senior crew retires.

Oil & gas

Procedure discipline across critical operations

Capture the operating know-how that keeps wells, separators, and compression trains running safely before your senior engineers retire.

Specialty chemicals

Reaction and drying expertise, preserved

The intuition that keeps yield up isn't in the binder. ExpertFlow AI gets it into the system before it leaves.

Automotive & tier-1

Plant-to-plant standardization

Six plants. One procedure of record. Differences explainable by data, not by who's on shift.

Energy & utilities

Defensible procedure, every audit

Compliance evidence built into the workflow not assembled in a panic the week before inspection.

We don't measure AI usage.We measure what's real.

These are the numbers customers track once both products are live proof the procedure is real and the plant is running better because of it.

<1hr

Time to approved SOP

From the moment an expert sits down to a published, signed-off procedure.

↓62%

Expert edit rate

Edits get smaller over time. Smaller edits mean the AI is learning your plant and doing its job correctly.

↓45%

Onboarding time

How long until a new engineer reaches independent operation measured against the binder.

↓38%

Shift-to-shift variability

The metric that proves the procedure isn't just written it's actually being used.

“The first session felt like a revelation.Twenty minutes in, I had a draft that captured thingsI'd been trying to write down for twelve years.”

Start the pilot

Every plant has a Max.Capture his knowledge.

See how OptiStudio and ExpertFlow AI work on your plant.

20-minute demo · No commitment required · Your data stays yours