Process & Production Technology
We unite manufacturing, engineering, chemistry, and technology across OT/IT, data, and process control — measurable KPIs, ISA-95 alignment, and field reliability at the core of design.
15+
Years in process industry
2.4M
Sensor readings / day
ISO
27001 & IEC 62443
15+
Years process experience
120+
Plants commissioned
48
Chemistry & mfg clients
99.2%
Platform uptime SLA
Expertise
From production lines to the reactor hall — measurable engineering and a unified data backbone.
MES, line balance, OEE, and lot traceability — zero blind spots between production plan and shop-floor reality.
Feasibility, P&ID digitization, FAT/SAT, and multidisciplinary integration — we reduce project risk in early phases.
Reactor control, formulation management, LIMS integration, and process safety — a live digital twin for chemical assets.
Edge AI, historians, API platforms, and corporate visibility — the layer that turns data into decisions and automation.
Platform products
From MES to OT security — one tenant, one API, independently licensable modules.
Tenant, licensing, audit trail, and event bus — shared backbone for all modules.
OEE, Andon, shifts, and ERP lot sync — line-based configuration.
Batch engine, reactor sequences, APC, and alarm rationalization.
LIMS, COA, and release workflows — GMP traceability built in.
Virtual commissioning, scenario library, and historian replay.
Historian, stream processing, and secure data API — OT→IT bridge.
Field gateway, offline-first operator UI, and edge AI inference.
IEC 62443 zone/conduit, anomaly detection, and patch governance.
Capabilities
From chemical process safety to MES integration — field and lab on the same data model.
Advanced PID, cascade, and MPC for reactors, columns, and mixing trains — targeting up to 40% reduction in spec deviation.
Details →Real-time shift, machine, and operator KPIs; bidirectional lot and material flow with ERP.
Details →Virtual commissioning from process parameters — scenario libraries that shorten go-live by weeks.
Details →Historian, stream processing, and secure APIs — opening OT data to IT and analytics without latency tax.
Details →Auto-link samples, COAs, and release tests to production recipes — eliminating manual transcription risk.
Details →Zone/conduit design, anomaly detection, and patch governance — security maturity without stopping production.
Details →Industries
Ready data models, integration templates, and KPI packs per sector.
From discovery to go-live — measurable deliverables and documented engineering at every phase.
Walk-down, P&ID, and data inventory — clear roadmap in 2 weeks.
ISA-95 layers, security zones, and rapid prototype to de-risk.
PLC/DCS/SCADA/MES integration and FAT — documented deliverables.
SAT, operator training, and 90-day KPI hypercare period.
Integrations
ERP, DCS, LIMS, and SOC — standard protocols and ready connectors.
SAP
ERP
Oracle
ERP
Siemens
Automation
Rockwell
Automation
Honeywell
DCS
OPC-UA
Protocol
MQTT
Protocol
Kafka
Data
PostgreSQL
Data
LabWare
LIMS
OSIsoft PI
Historian
Splunk
SOC
Technology portfolio
From process automation to OT security — modules tailored for chemistry and manufacturing.
DCS/PLC, batch management, and reactor sequencing for chemical and food processes.
OEE, downtime analytics, and operator terminals — line visibility in one pane.
Bridges linking lab results to recipes and release decisions.
Virtual commissioning, APC sandbox, and historian replay — cloud-edge simulation.
Historian, edge analytics, and secure APIs — OT/IT convergence.
IEC 62443, segmentation, and 24/7 anomaly monitoring.
Real-time SPC, hold/release, and quality gates — integrated with MES.
Steam, power, and fuel optimization — historian-backed energy KPIs.
GraphQL, webhooks, and tenant APIs — hybrid and SaaS deployment models.
GMP, environmental, and safety reports — automated audit packs.
Alarm rationalization, operator screens, and historian bridge — migrate legacy SCADA to an API-first platform.
Failure prediction from vibration, temperature, and historian data — CMMS work-order integration.
Petrochemicals, pharma, metals, and energy — references commissioned with measurable outcomes.
2025 · European petrochemical producer
2025 · GMP-certified facility
2024 · Automotive supply chain
2024 · Energy & chemistry holding
2025 · Multi-line food producer
2025 · Polymer production site
2026 · E-mobility supplier
2024 · Municipal utilities
18% raw material savings
Reactor APC Optimization
Release time −62%
Automated Batch Release
IEC 62443 Level 3
OT Segmentation & SOC
OEE 71→89
Line OEE & Andon
Unplanned downtime −31%
Edge AI Downtime Prediction
Sample SLA +45%
LIMS Throughput Gain
3 sites / 1 tenant
Multi-Site API Consolidation
Alarm flood −40%
SCADA Alarm Rationalization
Why Gunkel
Not consulting — a licensable platform, measurable KPIs, and fast integration.
Modular licensing — new lines or sites added in hours via configuration.
Critical control and operator UI keep running through cloud outages.
Standard REST/GraphQL and webhooks — ERP/LIMS integration in days, not months.
IEC 62443, audit trail, and tenant isolation by default.
References
ChemOrion
Petrochemicals
PharmaLine
Pharma / GMP
SteelForge EU
Metals
PolymerX
Polymers
TitanEnergy
Energy
BioPharm Global
Biotech
FlexPack TR
Packaging
GreenWater Utilities
Water
Customer experience
“The cloud-edge API layer unified three sites in one tenant — ERP integration went live in 9 days via GraphQL.”
Markus K. — NordProcess
“The APC and digital twin platform cut spec deviation; edge API and historian on one tenant — integration took weeks.”
Dr. Lars M. — ChemOrion
“The MES–LIMS bridge cut batch release time by more than half — full traceability for our GMP audit.”
Ayşe T. — PharmaLine
“OT segmentation moved us to IEC 62443 maturity without stopping production; SOC integration was flawless.”
James R. — SteelForge EU
“SCADA modernization and alarm flood project finished in 6 weeks — operator screens now talk to the historian in real time.”
Sofia L. — GreenWater Utilities
“Predictive maintenance cut unplanned downtime by 28%; CMMS work orders open automatically.”
Tom H. — TitanEnergy
How to tie HAZOP findings to live alarm and interlock matrices.
6 min read
A practical checklist to prevent lot-breakage costs in chem and pharma.
5 min read
Fault signals 14 days ahead from vibration and current signatures.
7 min read
One namespace, many vendors in chemical plants — a practical architecture guide.
7 min read
Zones, conduits, and patch governance — maturity without stopping production.
9 min read
Retention and edge tier strategy in a 2.4M readings/day scenario.
6 min read
From LIMS results to electronic release — eliminating manual steps.
8 min read
A six-month payback model for virtual commissioning investment.
10 min read
Real-time Western Electric rules on the operator screen with automatic hold.
6 min read
FAQ
Both: edge nodes on-premise, central management hybrid or full SaaS. Chemical plants typically use edge + private cloud.
PoC in 2–4 weeks via OPC-UA/MQTT gateway; full MES integration 8–16 weeks depending on plant size (demo estimates).
Module + line/reactor count + tenant — volume discounts for multi-site holdings. WHMCS integration on the roadmap.
Audit trail, e-sign, and zone/conduit design on-platform; certification completed with customer validation.
Technical intro within 48 hours, sandbox tenant and sample datasets — live plant connection in the POC phase.
Business hours, 24/7 critical, and dedicated TAM tiers — uptime SLA target 99.2% (demo).
Trusted by industry leaders
ChemOrion
Petrochemicals
PharmaLine
Pharma / GMP
SteelForge EU
Metals
PolymerX
Polymers
TitanEnergy
Energy
BioPharm Global
Biotech
FlexPack TR
Packaging
GreenWater Utilities
Water
ChemOrion
Petrochemicals
PharmaLine
Pharma / GMP
SteelForge EU
Metals
PolymerX
Polymers
TitanEnergy
Energy
BioPharm Global
Biotech
FlexPack TR
Packaging
GreenWater Utilities
Water
