Current installation analysis
Automated assessment of control efficiency. Visualisation of the Q-H and η(Q) curve, identification of distance from BEP (Best Efficiency Point), measurement of energy losses.
WaveFlow System Solutions 4.X
Real-time energy consumption optimisation for pumps, compressors and fans. A combination of machine learning (ML) algorithms and classical control in a single system — reduced energy use, same results, measurable return on investment.
System architecture
ControlFlow combines two proven technologies into a single synergistic control system. The classical PID controller delivers precise maintenance of process parameters, while the machine learning model minimises electrical energy consumption in real time.
The result is an installation that delivers the required flow or pressure — and does so at the lowest physically possible cost, hour after hour, all year round.
Reading real operating parameters from existing infrastructure (pressure, flow, power). PLC/SCADA integration without hardware replacement.
Searches the configuration space and selects the combination that minimises power draw while satisfying process constraints.
Maintains the required flow or pressure setpoint with full precision and disturbance rejection. Process continuity is always the priority.
Real-time savings monitoring, ESG/CO₂ reports, installation operating history, hourly tariff tracking.
Key features
ControlFlow is a complete control ecosystem — from analysing the current operating point, through optimising a single machine, to managing a pump cascade with millisecond precision.
Automated assessment of control efficiency. Visualisation of the Q-H and η(Q) curve, identification of distance from BEP (Best Efficiency Point), measurement of energy losses.
Two setpoint modes: constant flow Q or constant pressure H. ML shifts the operating point closer to BEP and holds it there regardless of network changes.
Intelligent selection of the number of active pumps. The ML algorithm searches all combinations and selects the cheapest one that satisfies the hydraulic target.
The system accounts for the real sector-specific demand profile and variable energy prices throughout the day. Greater savings during peak tariff hours.
Comparison of energy costs without and with ControlFlow over a 5-year horizon. Automatic calculation of the breakeven point, monthly and annual savings.
Automatic conversion of saved energy into CO₂ reduction (0.76 kgCO₂/kWh). Data ready for ESG, CSRD and environmental audit reporting.
Dedicated sectors
ControlFlow is tailored to the specifications of different industrial sectors — predefined daily profiles and parameter ranges correspond to real installations in each industry.
Water utilities
Treatment plants, pumping stations, distribution networks. Continuous 24/7 operation with daily demand peaks.
Industry
Cooling systems, process circuits, CIP. Shift work, high pressures, variable loads.
HVAC
Air conditioning, ventilation, heating systems in office buildings and industrial facilities. Midday peak, night minimum.
Wastewater
Municipal sewage pumping stations, stormwater lift stations. Two daily peaks, night minimum.
Food & Beverage
Production lines, cold storage, CIP systems, media transport — strict sanitary requirements.
Value for the client
ControlFlow generates energy savings that can be precisely calculated before deployment. Below are typical results for a 4 × 30 kW pump installation in the water utility sector.
At current electricity prices
Typical payback period after deployment
No production downtime required
PID reliability + ML intelligence
Saved electrical energy directly translates into a reduced carbon footprint. Data ready for ESG, CSRD and environmental audit reporting.
Technical specification
A system designed for demanding industrial environments — deterministic, secure and easy to integrate with existing control infrastructure.
ML model (optimisation) – searches the pump regulation space, minimises the objective function (power × tariff price), online updates.
PID controller – precise maintenance of the pressure or flow setpoint, VFD control, disturbance rejection.
Cascading – dynamic pump system control based on the current operating point and hydraulic constraints.
Hourly tariffs – weighted optimisation incorporating variable energy prices.
Interfaces – PLC (Modbus RTU/TCP), SCADA, BMS, optionally standalone on edge computing.
Calibration – 1–2 hours for a typical installation. Parameterisation from the nameplate or documentation.
Input modes – On/Off, fixed speed, VFD+PID. The system adapts to existing infrastructure.
Dashboard – web interface EN/PL, PDF reports, historical data export.
Flow Q – wide capacity range adapted to the specifics of the installation and sector.
Pressure H – full support for low- and high-pressure installations with automatic unit conversion.
Pump power – calculated from real operating parameters, verified against technical documentation.
Efficiency η – the system always drives operation towards the optimal BEP, minimising energy losses.
Savings – real time: daily, monthly, annual in currency and kWh.
CO₂ emissions – automatic calculation [t CO₂/year], ESG export.
ROI analysis – 5-year chart, automatic breakeven point, costs vs. savings.
Daily profile – demand history, hourly tariffs, savings windows.
Deployments and results
A real-world implementation of the optimisation system on a four-pump setup with a combined power of 740 kW. Results measured operationally, without replacing any equipment.
Ready to implement?
The interactive ControlFlow calculator lets you calculate potential savings, implementation cost and return on investment for your specific installation in just 5 minutes.
More information is available on desktop or tablet.
