Glass manufacturing's most energy-intensive step—melting—demands precise balance of quality, throughput, and energy amid complex dynamics, variable inputs, and changing conditions. SymphonyAI's Performance 360™ revolutionized furnace operations through AI-driven digital twins that forecast temperatures, pressures, oxygen levels, energy consumption, quality, and emissions. Real-time optimization delivered adaptive advisories and optimal setpoints for fuel flow, air-fuel ratios, and electric boosting—tightening temperature distributions, cutting fuel use, boosting production, and meeting constraints. For a typical 60TPD plant, this generated $1-3MM in revenue gains while ensuring compliance.

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