Hyperion deploys HYPPOS AI soft sensors at HELLENiQ ENERGY polypropylene plant in Greece
- Real-time AI-driven quality prediction supports off-spec reduction, faster grade transitions and lower carbon intensity at the Thessaloniki site.
Hyperion Systems Engineering Ltd. has successfully installed and commissioned its HYPPOS AI soft-sensor system at HELLENiQ ENERGY’s polypropylene production facility in Thessaloniki, Greece.
The deployment gives plant operators real-time predictions of key quality parameters, including Melt Flow Rate (MFR) and Xylene Solubles (XS), using data already available from the plant’s existing infrastructure. HYPPOS AI integrates with the site’s distributed control system (DCS), real-time databases, LIMS and enterprise systems, and does not require new analyzer hardware.
By combining machine-learning with live process data, the system closes the gap between laboratory testing and operational decision-making. Updated soft-sensor readings are generated every few minutes, giving operators continuous visibility during production and especially during grade transitions.
The implementation followed a phased approach that included scoping and feasibility, KPI and ROI definition, model development, shadow validation against laboratory results, a go/no-go review, and live rollout through the HYPPOS Operations User Interface.
According to figures presented by HELLENiQ ENERGY at SuSChemE-SUSTENS2 in Athens, the HYPPOS deployment delivered a 20% reduction in off-spec material, a 25% shorter grade-transition time, an estimated €350,000 in annual margin uplift, and 10.5 kt of CO₂ reduction per year.
The deployment forms part of a wider international rollout of HYPPOS AI, with pilots underway across Europe and additional pilots planned in Latin America and the Middle East.
“At HELLENiQ ENERGY, we continuously seek technologies that strengthen operational excellence and support our sustainability objectives,” said Dr. Aristi Bachtsi, Chemicals Production & Distribution Manager, HELLENiQ Petroleum S.A. “The successful deployment of HYPPOS AI demonstrates how advanced artificial intelligence can be translated into practical improvement inside an operating industrial plant, enabling better decision-making, improved quality control, and more efficient use of energy and materials”.
HYPPOS AI combines machine-learning, first-principles engineering knowledge, process analytics and industrial domain expertise for use in demanding process environments where accuracy, explainability, and operational trust are essential.
“Innovation succeeds when it is implemented in the real operating environment,” said Dr. Symeon Kassianides, Chairman and CEO of Hyperion Systems Engineering Group. “This project is a strong example of how process engineering, operational collaboration, and artificial intelligence can deliver measurable value in industry. The cooperation with HELLENiQ ENERGY shows how digital tools can support more efficient, competitive, and sustainable production”.
As industrial companies accelerate digital transformation, AI soft sensors are becoming more relevant for improving performance without major new capital investment. HYPPOS AI is positioned to help manufacturers reduce waste, improve quality, recover margin, and lower carbon intensity using data already available inside the plant.
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