RECOBA · Project

Smart Sensors and Real-Time Control That Cut Waste in Batch Manufacturing

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Imagine running a huge industrial oven or reactor where you're basically cooking blind — you set the timer and hope for the best. RECOBA built smart sensors and software that let factories watch what's happening inside their batch processes in real time, like putting a thermometer and quality checker right into the mix. When something starts going off track, the system automatically adjusts — saving energy, raw materials, and avoiding ruined batches. They tested this across three very different industries: chemicals, steel, and silicon metal.

By the numbers

consortium partners across value chain

countries represented in consortium

global industrial players validating the technology

total project deliverables produced

demo deliverables with working prototypes

SMEs in consortium

55%

industry partner ratio in consortium

The business problem

What needed solving

Batch manufacturing processes — from chemical reactors to steel furnaces — often run on fixed schedules with limited visibility into what's actually happening inside. This leads to wasted energy, lost raw materials, and inconsistent product quality because deviations are discovered too late to correct. Manufacturers need real-time monitoring and automatic process adjustment to catch problems while they can still be fixed.

The solution

What was built

The project built fibre optical temperature sensors for high-temperature batch processes, coverage efficiency sensors for monitoring heat loss by radiation, specialized sensors for steelmaking, and detailed dynamic process models. These feed into integrated control modules that track product quality in real time and automatically correct deviations during production — across 30 total deliverables with 4 demonstrated prototypes.

Audience

Who needs this

Steel producers running batch furnace or converter operationsChemical and polymer manufacturers with batch reactor processesSilicon metal and ferroalloy smelting companiesProcess equipment manufacturers looking to add smart sensing capabilitiesIndustrial automation integrators serving batch manufacturing clients

Business applications

Who can put this to work

Steel manufacturing

enterprise

Target: Steel producers running batch furnace operations

If you are a steel manufacturer dealing with inconsistent batch quality and wasted energy in furnace operations — this project developed new sensors specifically designed for steelmaking processes that monitor temperature in real time. Combined with dynamic process models, these sensors enable automatic corrections during production rather than discovering problems after the batch is finished. The system was validated with ThyssenKrupp Steel Europe, one of 3 global players in the consortium.

Chemical and polymer production

enterprise

Target: Chemical companies operating batch reactors

If you are a chemical or polymer producer struggling with batch-to-batch variation and energy waste in reactor operations — this project built fibre optical temperature sensors that withstand high-temperature fluids during batch processing. The integrated control system tracks product quality evolution and derives corrective actions automatically. BASF SE coordinated the project and validated the technology across 11 consortium partners.

Silicon and specialty metals

enterprise

Target: Silicon metal and ferroalloy producers

If you are a silicon metal producer facing high energy costs and raw material losses in smelting operations — this project developed coverage efficiency sensors that monitor temperature loss from high-temperature fluids by radiation. The real-time control modules are designed to be easily adaptable to existing batch processes, reducing the need to replace current equipment. Elkem was one of 3 global industry players validating the technology.

Frequently asked

Quick answers

What would this cost to implement in our plant?

Pricing details are not available in the public project data. The consortium developed business models specifically to approach industrial sectors for market entry, suggesting commercialization was planned. Contact the coordinator (BASF SE) or technology partners for implementation costs.

Has this been tested at industrial scale?

Yes. The technology was developed and validated with 3 global industrial players: BASF (polymers), ThyssenKrupp Steel Europe (steel), and Elkem (silicon metal). The consortium included 6 industry partners out of 11 total, representing a 55% industry ratio. Demo deliverables confirm working sensor prototypes and dynamic process models were produced.

Who owns the IP and can we license this?

The project was funded as a Research and Innovation Action under Horizon 2020 with 11 partners across 6 countries. IP is likely shared among consortium members including BASF SE as coordinator. Licensing arrangements would need to be discussed directly with the relevant technology owners in the consortium.

Can this work with our existing batch equipment?

The objective explicitly states the control modules were designed to be 'easily adaptable to existing batch processes in various industrial sectors.' The cross-sectorial approach — validated in polymer, steel, and silicon metal industries — suggests the system was built for retrofit rather than greenfield installations.

What specific sensors were developed?

Based on deliverable data, the project produced: fibre optical temperature sensors for monitoring high-temperature fluids during batch processing, coverage efficiency sensors to monitor temperature loss by radiation, and new sensors specifically designed for steelmaking processes. A total of 30 deliverables were produced across the project.

Is this technology ready for deployment now?

The project closed in December 2017. The consortium developed business models for market entry, and 4 demo deliverables confirm working prototypes were validated with industrial partners. However, current commercial availability should be confirmed directly with BASF SE or the technology-developing partners.

Consortium

Who built it

The RECOBA consortium is exceptionally strong from a business perspective. Led by BASF SE — one of the world's largest chemical companies — the 11-partner team spans 6 countries and includes 3 global industrial players across different sectors: BASF (polymers), ThyssenKrupp Steel Europe (steel), and Elkem (silicon metal). With a 55% industry ratio (6 out of 11 partners), the project was heavily driven by real manufacturing needs rather than pure academic interest. The inclusion of 3 SMEs alongside 4 universities and 1 research organization ensured both practical implementation capability and scientific depth. This cross-sectorial composition means the resulting technology was stress-tested across fundamentally different batch processes, increasing its adaptability to other manufacturing environments.

BASF SECoordinator · DE
VDEH-BETRIEBSFORSCHUNGSINSTITUT GMBHparticipant · DE
THE CHANCELLOR MASTERS AND SCHOLARS OF THE UNIVERSITY OF CAMBRIDGEparticipant · UK
CYBERNETICA ASparticipant · NO
RHEINISCH-WESTFAELISCHE TECHNISCHE HOCHSCHULE AACHENparticipant · DE
VYSOKA SKOLA CHEMICKO-TECHNOLOGICKA V PRAZEparticipant · CZ
ELKEM ASAparticipant · NO
UNIVERSIDAD DEL PAIS VASCO/ EUSKAL HERRIKO UNIBERTSITATEAparticipant · ES
THYSSENKRUPP STEEL EUROPE AGparticipant · DE

How to reach the team

BASF SE (Germany) coordinated this project. SciTransfer can help arrange an introduction to the right technical contact within the consortium.

Order a report on this consortium See BASF SE profile →

Next steps

Talk to the team behind this work.

Want to know if RECOBA's batch process sensors and control technology fit your production line? SciTransfer can assess your specific use case and connect you with the right consortium partner.

Order a report on this topic More in Manufacturing & Industry 4.0