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ProPAT · Project

Affordable Smart Sensors That Let Factories Control Quality in Real Time

manufacturingTestedTRL 6
pro-pat.eu

Imagine running a factory where you only find out something went wrong after the batch is already ruined. ProPAT built affordable sensors and a smart software platform that watch your production line like a hawk — measuring what's in your mix, how fine the particles are, and whether temperature and pressure are drifting. It's like giving your factory a nervous system that feels problems before they become expensive. The system even learns from past runs so it can predict trouble and adjust automatically, keeping everything at the sweet spot between cost and quality.

By the numbers
17
consortium partners across 8 countries
7
industry partners validating the technology
5
SMEs in the consortium
11
project deliverables completed
41%
industry ratio in consortium
The business problem

What needed solving

Process industries lose significant money when manufacturing conditions drift even slightly from optimal — leading to off-spec products, wasted materials, and costly rework. Traditional process monitoring equipment is expensive and often provides results too late to prevent quality issues. Manufacturers need affordable, real-time process control that catches problems before they become expensive.

The solution

What was built

ProPAT built low-cost MEMS-NIR spectroscopic and granulometric analysers, smart sensors for temperature, flowrate and pressure, and integrated them into a global control platform with self-learning and predictive capabilities. A beta prototype of the ProG instrument was delivered and validated on mineral milling, ceramics, pharma granulation, and resin polymerization.

Audience

Who needs this

Pharmaceutical manufacturers running granulation and mixing linesCeramics and mineral processing companies with milling operationsChemical companies running polymerization reactorsMetal powder producers needing particle size controlAny process industry plant looking to replace expensive PAT equipment with affordable alternatives
Business applications

Who can put this to work

Pharmaceuticals
enterprise
Target: Pharma manufacturers doing mixing and granulation

If you are a pharmaceutical manufacturer dealing with batch-to-batch inconsistency in granulation and mixing — this project developed low-cost MEMS-NIR spectroscopic analysers integrated into a self-learning control platform that monitors composition and particle size in real time. The system was validated specifically on pharma mixing and granulation processes across a consortium of 17 partners. It enables Quality by Design so you catch deviations before they turn into rejected batches.

Ceramics & Minerals Processing
mid-size
Target: Ceramics producers and mineral milling operations

If you are a ceramics or minerals company struggling with inconsistent milling output and high waste rates — this project built smart granulometric analysers and a global control platform tested on milling of minerals, ceramics, and metals. The system provides near real-time closed-loop control so your milling process stays at its optimum. With 7 industry partners involved in validation, the technology was designed for real factory conditions, not just labs.

Chemical & Polymer Manufacturing
enterprise
Target: Resin and polymer producers

If you are a chemical company running polymerization processes where small deviations from optimal conditions lead to off-spec product and costly rework — this project developed smart sensors for temperature, flowrate, and pressure combined with predictive software that learns from your process history. The platform was validated on resin polymerization and is designed to dramatically reduce overcosts from even slight process deviations.

Frequently asked

Quick answers

How much does the ProPAT system cost compared to traditional process control?

The project specifically targeted "low cost" MEMS-NIR spectroscopic and granulometric analysers as an alternative to expensive traditional PAT equipment. Based on available project data, exact pricing is not published, but the design goal was affordability for wider industrial uptake. Contact the coordinator for current pricing or licensing terms.

Can this scale to full industrial production lines?

Yes — the system was validated across multiple industrial processes including milling of minerals, ceramics, and metals, pharma granulation and mixing, and resin polymerization. With 7 industry partners and 5 SMEs in the consortium across 8 countries, the technology was tested under real production conditions, not just laboratory settings.

What is the IP situation — can we license this technology?

ProPAT was funded as a Research and Innovation Action (RIA) under Horizon 2020 with 17 consortium partners. IP is typically shared among partners according to consortium agreements. IRIS Technology Solutions (Spain), the coordinating SME, would be the first point of contact for licensing discussions.

Is this compliant with pharma regulations like FDA PAT guidance?

The project explicitly targets Process Analytical Technologies and enables Quality by Design — both concepts aligned with FDA and EMA regulatory expectations for pharma manufacturing. Based on available project data, specific regulatory certifications are not mentioned, but the approach follows established PAT principles.

How long does it take to integrate into an existing production line?

Based on available project data, specific integration timelines are not published. However, the platform was designed as a versatile global control system for data acquisition and processing, with smart sensors that can be integrated into both batch and continuous processes. The 17-partner consortium validated integration across multiple industrial settings.

What kind of support or training is available?

The consortium includes 6 universities and 3 research organizations alongside 7 industry partners, suggesting strong technical support capacity. Beta prototypes of the ProG instrument were delivered as a demo. Contact the coordinator at IRIS Technology Solutions for details on current support and training options.

Does this work for both batch and continuous processes?

Yes — the project explicitly developed smart sensors for both batch and continuous processes. The global control platform integrates data from all sensor types and provides self-learning and predictive capabilities regardless of whether your operation runs in batch or continuous mode.

Consortium

Who built it

The ProPAT consortium is strong and well-balanced for industrial uptake: 17 partners from 8 countries with a healthy 41% industry ratio. The mix of 7 industry partners and 5 SMEs alongside 6 universities and 3 research organizations means the technology was developed with real factory needs in mind, not just academic curiosity. The coordinator is IRIS Technology Solutions, a Spanish SME — meaning a commercially-minded company drove the project rather than a university lab. This kind of consortium structure typically produces results that are closer to market-ready.

How to reach the team

IRIS Technology Solutions, S.L. (Spain) — an SME specializing in technology solutions. Search for their current team via LinkedIn or their company website for process control inquiries.

Order a report on this consortiumSee IRIS TECHNOLOGY SOLUTIONS, SOCIEDAD LIMITADA profile →
Next steps

Talk to the team behind this work.

Want to explore how ProPAT's affordable sensor platform could fit your production line? SciTransfer can connect you directly with the right people in the consortium — saving you weeks of research and cold emails.

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