We turn Factories into Autonomous Agents - with Causal AI Solution
Grade: C — Score: 50/100
Vernaio's Process Booster X (PBX) leverages breakthrough Causal AI technology to analyze raw process data, enabling manufacturers to understand the real cause-and-effect dynamics of their production lines. This allows for optimal adjustments to be made with minimal expert input.
The workflow involves continuous monitoring of critical KPIs, predicting deviations, and executing real-time adjustments to enhance performance. This shift from conservative to confident operations results in significant cost savings and improved efficiency.
However, the risks of not adopting such technology include hidden inefficiencies that can drain margins and lead to excessive energy use and wasted materials. By implementing PBX, manufacturers can mitigate these risks and achieve stable quality and lower operational costs.
Custom Enterprise Pricing: Quote-based (request a discovery call)
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Process Booster X (PBX) is Vernaio's real-time process optimization platform for manufacturing. It uses the aivis Causal AI engine to build a line-specific causal master model directly from raw production data with minimal expert input. In live operation, PBX acts as a co-pilot (recommending setpoint adjustments to operators) or autopilot (executing adjustments automatically within guardrails). It optimizes cost, quality, throughput, and energy simultaneously rather than treating them as separate objectives.
Traditional AI approaches (neural networks, LLMs) identify correlations in data but cannot distinguish cause from effect. Vernaio's aivis engine discovers true causal structure through invariants found in interventional data (how the system responded to past setpoint changes). It uses uncertainty-aware Gaussian Process predictors and stochastic differential equations to separate deterministic process laws from random fluctuations. This means PBX can simulate counterfactual what-if scenarios and compute the smallest constraint-safe adjustments, rather than just predicting outcomes.
Vernaio currently deploys Process Booster X in pulp and paper manufacturing, nonwoven fabrics production, gelatin and collagen processing, and heated tobacco production. The platform is industry-agnostic and applicable to any complex, dynamic, data-rich production process. Vernaio states that PBX can be applied wherever operators are managing thousands of changing signals and running conservative settings that leave performance on the table.
Vernaio claims annual production cost reductions in the high six-figure range, up to 1 million EUR per line, through reduced material consumption (fewer safety margins and less overuse), lower energy use (optimized settings instead of conservative defaults), and increased stability (fewer deviations and less scrap). The company reports ROI within the first year of deployment, with the first production line going live within 3 months of engagement.
Vernaio follows a three-step onboarding process. Step 1 is a discovery call (60 minutes). Step 2 is a free preliminary analysis (results in 2 weeks) where Vernaio evaluates your historical production data under NDA and provides a quantified savings estimate. Step 3 is deployment, with the first production line going live within 3 months. The company has achieved a 94% success rate across 30+ industrial IoT projects.
Vernaio is a selected member of SynerLeap, ABB's innovation growth hub that connects top industrial startups with ABB's networks, clients, industrial partners, and technology. This partnership gives Vernaio access to ABB's global ecosystem for faster scaling and expanded industrial reach. Additionally, Voith GmbH (a global industrial technology company specializing in energy, paper, and transport) is a shareholder in Vernaio.
No. The aivis engine is designed to work with raw, unlabeled shop floor data and requires minimal expert input. It automatically handles time synchronization, feature engineering, and model selection. Process engineers and operators interact with PBX through setpoint recommendations and real-time KPI dashboards rather than writing code or building models. The platform is built for plant managers, process engineers, shift supervisors, and operators.
Vernaio GmbH is headquartered in Munich, Germany and operates under EU data protection jurisdiction (GDPR compliant). Historical production data shared during the preliminary analysis phase is protected under NDA. The company publishes a privacy policy and security disclosure page on its website. Vernaio's aivis engine processes production process data (sensor signals, setpoints, KPIs), not personally identifiable information.