Real time PLC data collection
Pull flow rates, temperatures, and other key process data directly from your PLCs in real time, so every batch gets consistent data without an operator having to collect it.
Bulk Chemical
Batch consistency and safety compliance across every reactor and blend.
Bulk chemical manufacturers run continuous processes and batch operations that live and die by consistency. Essembi pulls reactor and blending data straight from your PLCs, so consistency doesn't depend on an operator remembering to write it down.
Where Essembi Pays Off
Where Essembi pays off on your bulk chemical floor.
The specific ways bulk chemical manufacturers put Essembi to work, from the reactor to the blend tank.
Flow meter tracking
Track flow meter readings across every reactor and blending line to catch a rate that has drifted off target before it turns into an off spec batch.
Bulk tank tracking
Track bulk tanks with real time quality statuses, flush data, and other key metrics.
Preventive and corrective maintenance
Manage preventive and corrective maintenance for reactors and blending equipment in one system.
Maintenance aware scheduling
Build production schedules that incorporate changeovers and maintenance activities together.
In process quality and safety checks
Complete key quality and safety checks at the start of the job and at regular intervals on hazardous reactor and blending processes.
Before Essembi
Flow and batch data that only exists in an operator's memory
Flow rates, temperatures, and batch timing get logged by hand when someone remembers to, and remembered a little differently by every operator, so the data leadership sees is really just whoever happened to write it down.
With Essembi
Flow meter and PLC data captured automatically, every batch
Essembi pulls flow meter readings and other key process data directly from your PLCs in real time, so every batch has a complete, consistent record without relying on an operator to collect it by hand.
Contract Manufacturing
Built for contract bulk chemical manufacturers too.
Running production for other brands changes what your team needs to track. Essembi gives your operations and sales teams the data to price, plan, and sell with confidence.
- Track key data that goes into pricing, like run rates and labor costs
- Understand capacity and utilization on key reactors so your sales team knows where to focus for future orders
- Give your sales team real time visibility into batch progress with scheduling and production tracking
Everything Included
Every capability, included, down to the details.
No add-on modules, no separate logins, and no ceiling to grow into — every plan includes the full platform.
Production
- OEE Tracking Real time availability, performance, and quality by line, shift, and job.
- Production Scheduling One calendar for jobs, changeovers, and maintenance, not three disconnected systems.
- Unlimited Sensors on the Line A sensor after every key machine, not the one or two most platforms limit you to.
- Machine & PLC Integration Pull data directly from the equipment you already have on the floor.
- Bulk Scale Weight Capture Track bulk production rooms through connected scales, not a clipboard.
- Scan to Confirm Material Scan incoming material or components to confirm they belong on the job before production starts.
- Changeover & Centerlining Set and hold consistent machine set points by product and line, and track changeover time by job.
- Automatic Downtime Capture Stops are logged and associated with the right component automatically, no manual entry required.
Quality & Safety
- Customizable Quality Forms Build the exact in process checks your product and process require.
- CAPA & Corrective Actions Structured corrective action from root cause to verification, tracked to closure.
- Digital Batch Records An accurate, timestamped record of the process as it actually happened.
- Safety Incident & Near-Miss Tracking Capture incidents and near-misses in the same platform as production and quality.
Maintenance
- Work Order Management Create, assign, and track work orders from any device on the floor.
- Preventive & Corrective Maintenance Scheduled PMs and reactive repairs, tied to the assets that need them.
- Asset Health Tracking MTTR, MTBF, and maintenance cost by asset, not buried in a spreadsheet.
Workforce
- RFID Labor Tracking Badge on, badge off labor costing by job and formula, no tablets or logins required.
- Connected Workforce & Huddles Shift huddles, recognition, and skills tracking built into daily workflow.
- ERP Work Order Integration Jobs flow in from the ERP you already run, instead of getting re-keyed by hand.
AI
- AI Production Summaries AI reads thousands of data points a shift and tells you what actually matters.
- AI OEE Analysis AI reviews the components behind a score and explains what drove it, with suggestions to improve.
- Ask AI Any Question Plain language questions about your own data, answered in seconds, with follow ups.
- AI Pre-Job Briefing Operators get job history, downtime patterns, and trends to watch before the job starts.
Platform
- Native Dashboards & Drill-Downs Built in analytics and trend analysis, no separate BI tool required.
- Device Agnostic Runs on any device on the floor, phone, tablet, or laptop, not just an iPad.
- Vision & Camera Integration Tie camera footage directly to the moment a quality or safety event occurred.
- Advanced Customization Configured around how your process actually runs, not a rigid template.
- Cloud-Native SaaS No servers to manage and no expensive on-prem infrastructure to maintain.
