From Idle Time to Output: Cycle Time Analytics for Batch Reactors – Ecolab

Rebecca Hedges of Ecolab shares how her team used Seeq to uncover hidden efficiency losses in batch reactor operations by focusing on cycle time adherence rather than treating all processing time as value-added. The session walks through how Ecolab isolated batch steps, compared actual versus standard cycle times, surfaced variability across products, vessels, and shifts, and translated those findings into practical actions such as maintenance changes, planning updates, automation, training, and procedure improvements. By turning lost time into measurable financial impact, the approach helped demonstrate real business value, including a 7% increase in annual batches produced, a 10% reduction in the impact of over-cycle-time runs, and a potential $1 million absorption benefit when scaled across vessels.