Digital Twin, 
as a Service! 

Unlock up to 25% more capacity from your existing Prilling Tower.

Smarter prilling. Same process. Greater control. 
Book feasibility call here! 

Prilling towers have been installed worldwide. Many are over dimensioned by today’s standards. With the right setpoints tuned to the actual ambient and process conditions, a substantial increase in production capacity and quality is achievable.

Why this matters 

Small shifts in weather conditions, melt properties, or equipment condition can push performance off target, resulting in more off-spec prills, increased dust levels, and more cleaning stops. Trial-and-error approach can result in an average setpoint recommendation, for average production results, but it won’t reveal the ideal operating window on a daily basis.

A pathway to better performance 

Pre-scan (Client Declared Data) 

A rapid assessment based on the client’s unique tower dimensions, operating data, and melt properties. These data sets will be used to estimate:

• Potential capacity envelope (often up to +25%)
• Expected Particle Size Distribution (PSD) window
• Sensitivity to ambient and process variability
• Scaling on the tower wall and tower bottom
• Operational window of the Priller 

When to use: You want to see the upside fast, to decide if the journey is worth it.

Digital Twin as a Service (DTaaS) 

A bespoke, validated model of your tower that replicates every minute of operation and lets you test any change without risk. 

What we validate: 

• Exact dimensions of the tower and sensor positions (on-site survey)
• Physical properties of the melt (Kreber laboratory testing)
• Process model calibration against real plant data (on-site) 

What this unlocks: 

• Minute-by-minute replay of production runs
• Setpoint recommendations for capacity, PSD, dust reduction, scaling avoidance
• What-if scenarios for product specs, ambient shifts, and operating modes
• Virtual trials of OEM upgrades (IR cameras, bucket clogging detection, flow monitoring - PrillTech) before you invest 

When to use: You want a validated, ongoing performance engine. Not a one-off study. 

Prefer classic training? We offer on-site operator training & support. However, where operator skills decay and staff rotations create variability, DTaaS will reinforce best practices continuously with data, not with operator specific experience.

What you receive

Validated Digital Twin of your tower (hosted by Kreber) Baseline report + max (potential) capacity envelope OEM upgrade recommendations and impact forecasts Operator coaching notes tied to current conditions Scenario reports with setpoint guidance Service as a Subscription (SaaS): Monthly Bottleneck Report with constraints, root causes, actions

OEM innovation, de-risked 

• Infrared cameras temperature & wetting control
• Prilling bucket clogging detection flow stability
• Flow monitoring & control --> tighter PSD and capacity 

We provide impact forecasts and a prioritized upgrade roadmap inside your monthly report. 

From DTaaS to PrillTech (the next step) 
Once your team is comfortable with simulation-guided changes, PrillTech can intervene in real time—closing the loop faster than DTaaS. The prilling production will increase to new and improved levels. DTaaS proves the gains and builds trust; PrillTech scales them minute-to-minute.

FAQ

How real is "up to 25%" capacity?

Many towers are structurally capable of more. The achievable gain is site-specific and depends on melt properties, ambient conditions, internals, and current constraints. The Pre-scan shows the potential with the existing process; DTaaS validates and operationalizes it.

Will DTaaS disrupt production?

No. Modeling is offline. On-site measurements are planned to avoid interference with the typical production schedule.

Do we need to install software?

No. Kreber hosts your twin; you receive the reports and recommendations.

 

 

Operating a Prilling Tower?

Unlock your hidden capacity.

Book feasibility call