Industries
Built for plants that run on heat, speed, and uptime.
Setpoint is used wherever PLCs drive production. Here is how it maps to the problems in your part of manufacturing.
Plastics & extrusion
Hold every zone on target, every shift.
Extruders and molding presses live and die by barrel temperatures and line speed. Setpoint watches every zone and every start-up.
The challenge
- Heater bands that all switch on at once drive peak demand
- Nobody can say what heating a line actually costs per year
- Scrap during start-up is hard to quantify
- Zone drift is noticed only after a quality complaint
With Setpoint
- Heater insights turn heater energy into projected annual electricity cost at your rate
- Stagger recommendations come with an estimated dollar savings per year
- Uptime insights separate productive time from quality-loss running
- Predictive signals catch slowing warm-up and oscillating zones early
Setpoint / Plant 2 / Heater insights
Sample dataHeater insights
Start-up load · simultaneous vs staggered
Stagger candidateCost & savings — Plant 2
Savings opportunities
Several heaters often heat up in the same buckets — staggering start times may reduce peak demand. Highest-overlap asset groups: Line 3 (82/100), Line 1 (64/100), Line 4 (51/100). Stagger starts within each asset group — heaters on different asset groups don't need to coordinate.
~9.10 MWh this window ($1,092)
First crossing of ~85% of typical temperature spans up to 1.6 hours across heaters in the same asset group — align start times with true production-ready needs. Largest spread is within Line 1 (1.6 h). Preheat timing is compared within each asset group — heaters on different asset groups don't need to start together.
Metals & heat treating
See where the energy actually goes.
Furnaces, ovens, and induction lines are energy-hungry. Setpoint connects heating data to output so you can cut cost without risking spec.
The challenge
- Energy bills with no line-level breakdown
- Heating elements age quietly until they fail
- Recipe changes are not compared run over run
With Setpoint
- Heater insights estimate energy per asset group and highlight stagger candidates
- Warm-up slope tracking points to element or supply issues
- Tag insights compare temperatures and soak times by recipe
Setpoint / Plant 1 / Insights
Sample dataInsights
Recent Load ID— Heat treat
Summary by Load ID
| Detail | L-2047 7.0 h | L-2046 7.0 h | L-2045 7.0 h | L-2044 7.0 h | L-2043 7.0 h | L-2042 7.0 h | L-2041 7.0 h |
|---|---|---|---|---|---|---|---|
Furnace 2 | |||||||
Cycle · 3 tags | |||||||
Door Closed | 96% on | 96% on | 96% on | 96% on | 96% on | 96% on | 96% on |
Recipe | 4140 Q&T | 4140 Q&T | 4140 Q&T | 4140 Q&T | 4340 Q&T | 4140 Q&T | 4140 Q&T |
Soak Time min | 90.00 min | 90.00 min | 90.00 min | 90.00 min | 120.0 minunusual | 90.00 min | 90.00 min |
Quench · 1 tag | |||||||
Oil Temperature °F | 140.3 °F 132.7 – 146.5 | 142.8 °F 135.2 – 149.0 | 143.3 °F 135.7 – 149.5 | 141.8 °F 134.2 – 148.0 | 145.3 °F 137.7 – 151.5 | 140.8 °F 133.2 – 147.0 | 144.3 °F 136.7 – 150.5 |
Zone 1 · 2 tags | |||||||
Output % | 58.07 % 53.50 – 92.20 | 60.57 % 56.00 – 94.70 | 61.07 % 56.50 – 95.20 | 59.57 % 55.00 – 93.70 | 63.07 % 58.50 – 97.20 | 58.57 % 54.00 – 92.70 | 62.07 % 57.50 – 96.20 |
Temperature Actual °F | 1,538 °F 1,404.5 – 1,550.3 | 1,540.5 °F 1,407 – 1,552.8 | 1,541 °F 1,407.5 – 1,553.3 | 1,539.5 °F 1,406 – 1,551.8 | 1,543 °F 1,409.5 – 1,555.3 | 1,538.5 °F 1,405 – 1,550.8 | 1,542 °F 1,408.5 – 1,554.3 |
Zone 2 · 2 tags | |||||||
Output % | 65.43 % 61.60 – 92.60 | 85.61 %unusual 82.10 – 100.0 | 62.43 % 58.60 – 89.60 | 63.93 % 60.10 – 91.10 | 60.43 % 56.60 – 87.60 | 64.93 % 61.10 – 92.10 | 61.43 % 57.60 – 88.60 |
Temperature Actual °F | 1,542.9 °F 1,399.7 – 1,555.3 | 1,514.4 °Funusual 1,371.2 – 1,526.8 | 1,539.9 °F 1,396.7 – 1,552.3 | 1,541.4 °F 1,398.2 – 1,553.8 | 1,537.9 °F 1,394.7 – 1,550.3 | 1,542.4 °F 1,399.2 – 1,554.8 | 1,538.9 °F 1,395.7 – 1,551.3 |
Average by Load ID
Food & beverage
Batch-by-batch visibility, without the clipboards.
From cook kettles to packaging lines, Setpoint logs every batch parameter and keeps it tied to the product you were running.
The challenge
- Batch records live on paper or in disconnected HMIs
- Hard to prove a parameter held for the whole run
- Utilities and HVAC data sit in a separate building system
With Setpoint
- Tag insights summarize every signal for each batch or product code
- Warning and critical alarms on the limits you define for each parameter
- BACnet and KNX connections bring facility data into the same view
Setpoint / Plant 2 / Alarms
Sample dataActive Alarms (4)
- CRITICAL
Line3.Melt.Pressure
Line 3 · Extruder · 3,420 psi > 3,300
Pressure
2 min ago
- WARNING
Line3.Zone7.Temp
Line 3 · Zone 7 · 201 °C < 210
Temperature
14 min ago
- WARNING
Press4.Bearing.Vib
Press cell A · Press 4 · 7.1 mm/s > 6.5
Vibration
41 min ago
- CRITICAL
Chiller2.Return.Temp
Utilities · Chiller 2 · 19.8 °C > 18
Temperature
1 h ago
Packaging & converting
Turn downtime into a number you can manage.
High-speed lines lose minutes in small stops. Setpoint makes every stop and slow-down visible by line, shift, and day.
The challenge
- Micro-stops never make it into the shift report
- Running time is not the same as good-product time
- Every line reports uptime a little differently
With Setpoint
- Uptime insights classify time as productive, quality loss, or stopped
- Consistent definitions across every line and site
- Daily rollups ready for the morning production meeting
Setpoint / Plant 2 / Uptime insights
Sample dataUptime insights
Productive is enabled and running. Quality loss is moving but not good material. Stopped is not enabled.
State timeline
Automotive & discrete
Many cells, many PLC brands, one picture.
Mixed fleets of Rockwell, Siemens, and Beckhoff controllers are normal. Setpoint speaks to all of them and models each cell the same way.
The challenge
- Different controller vendors on every line
- Tag naming that varies from cell to cell
- Engineering time spent wiring up dashboards
With Setpoint
- One connection layer across Rockwell, Siemens, Beckhoff, and open protocols
- Frames and tag patterns standardize similar cells in minutes
- Edge devices per cell, managed from one central server
Setpoint / Connections / New connection
Sample dataNew connection
Allen-Bradley / Rockwell
ControlLogix / CompactLogix · EtherNet/IP · DF1
Siemens
S7 · PROFINET
Beckhoff
ADS / TwinCAT
Emerson
DeltaV
Open protocols
Modbus TCP · OPC UA · CANopen · Open Protocol
Building automation
BACnet/IP · KNXnet/IP
SQL databases
PostgreSQL · MySQL · SQL Server
Media
Watched image folders
Chemicals & process
Long-horizon data, kept and queryable.
Continuous processes need years of history. Setpoint archives every logged row to Parquet so compliance and analytics teams always have it.
The challenge
- Historian licenses that scale with tag count
- Data trapped on-site for audits and investigations
- Process engineers waiting on IT for exports
With Setpoint
- DeltaV and OPC UA connections into a modern time-series store
- Automatic Parquet archive to local disk and cloud object storage
- AI Chat and the REST API answer questions without a ticket
Setpoint / AI Chat
Sample dataAI Chat
Line 3 was stopped for 3.7 h on Wednesday, about twice its weekly average. Most of it came from two events:
- 06:10–07:35 · start-up after a die change. Zone 7 took 38 min longer than usual to reach setpoint.
- 14:02–15:20 · melt pressure went high and the operator disabled the line.
Zone 7 also shows a slowing warm-up in Heater insights. Want me to pull its temperature trend for the week?
Don’t see your industry?
If your process runs on PLCs, Setpoint can connect to it. Tell us about your lines and we will show you what is possible.