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@hyppos
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HYPPOS’ successful selection of Project EMBED-AI for funding by the Cyprus Research & Innovation Foundation
HYPPOS, Hyperion Predictive Production Online Software, is an innovative, all-in-one, deep tech, decision-support tool that integrates with production level and business management level IT components of manufacturing plants.
Hyperion has successfully released HYPPOS v.1.0 within the framework of the 2nd Opportunity grant from the Cyprus Research & Innovation Foundation.
Drawing from the HYPPOS-Machine Learning (ML) Smart Sensors project findings, through Project EMBED-Al, Hyperion has been seeking support towards the technological upscale, optimization, demonstration, and exploitation of HYPPOS-AI as an Industry 4.0 solution.
The image below illustrates the HYPPOS completed projects, deliverables, and technical readiness levels:
Hyperion Group is proud to announce that its HYPPOS-related project Embed-AI was selected for funding for by the Cyprus Research & Innovation Foundation within the context of Research in Enterprises (Bridge Programmes).
The main objectives of project EMBED-Al are:
1. Validate the scientific and technical targets of HYPPOS-AI prototype v.2 in an operational environment; and
2. Intensify Hyperion's research and development in AI/ML, and innovation activities.
The Cyprus Institute (CyI) is the participating research partner of Hyperion that will support the project with through its engagement through the technology transfer of AI/ML expertise to Hyperion.
Green polymers, natural polymers & HYPPOS
When it comes to polymers, green and natural aren't the same.
Natural polymers (biopolymers) occur naturally or are produced by living organisms. Natural polymers can be man-made from raw materials found in nature.
Green polymers are produced using green (or sustainable) chemistry. Green chemistry is the design of chemical products and processes that reduce or eliminate the use or creation of substances hazardous to humans and environment. Natural polymers are usually green.
In polymer production, green principles include:
Clean (no-waste) production process.
No use of additional substances (e.g., organic solvents).
High energy efficiency in manufacturing.
Renewable resource and energy usage.
No health and environmental hazards.
High safety standards.
Low carbon footprint.
Controlled product lifecycles with effective waste recycling.
HYPPOS is an integrated, easy-to-configure, fast-to-install, highly compatible, decision support tool for use in continuous and semi-continuous production plants.
HYPPOS already contributes to the above green principles by:
Resulting in a reduction of carbon dioxide emissions.
Reducing resource usage (e.g., energy, water and/or feedstock).
Enabling waste reduction, recycling, and renewable feedstock.
Polymer industry trends predicted to impact manufacturers beyond 2022
1. Sustainability
Original Equipment Manufacturers (OEM) are assuming more responsibility for sustainability by working with suppliers committed to low-waste or zero-waste initiatives and use recycled materials. Manufacturers are tasked with refining processes to include scrap reduction and/or recycling to aid the circular economy, along with introducing earth-friendly resins and additives.
2. Bio-resins & eco-friendly plastic additives
The environmental impact of traditional resins remains under close scrutiny, leading many manufacturers to reconsider their approach to selecting materials. Bio-resins are gaining traction as alternatives since they’re based on natural plant extracts or renewable resources, which aid in green practices through benefits such as safer disposal, energy-efficient manufacturing, and decreased toxic emissions.
3. Reinforced plastics
Carbon, glass, metal, and graphite-reinforced plastics are perhaps most notably embraced by the automotive industry as substitutes for metal components. They are also gaining popularity in medical and defense applications for their low weight, durability, and versatility.
4. Lightweight parts & tools
Given mandates surrounding improved gas mileage in traditional vehicles and longer battery life for hybrids and electric cars, lightweight parts remain a key focus for automotive OEMs. Medical OEMs are seeing shifts in how plastics are used within their industry, largely in concert with advanced technologies.
5. 3D printing & production efficiencies
3D printing is improving many aspects of plastics manufacturing and remains a catalyst for re-imagining options for plastic parts. Advancements in this technology are leading to some impressive results with direct benefits for certain OEMs, including prototyping.
6. Automation & industry 4.0
Automation is meeting the plastics industry demand for process simplification and cost savings. The advent of Industry 4.0 provides prime opportunities for further integration of robotic technologies and machine controls.
The above-mentioned trends connect with HYPPOS in many ways:
The implementation of HYPPOS can reduce resource usage, for example, energy, water, and/or feedstock.
HYPPOS enables waste reduction, recycling, renewable feedstock, and novelty.
HYPPOS can result in a reduction of 4 million kilograms of Carbon Dioxide per month per plant.
HYPPOS is an industry 4.0 product. See this blog post for more information.
Not all plastics are created equal: some are recyclable & some are not
Plastic is everywhere and we know it when we see it, but knowing the difference between the various types of plastic needs elaboration. Furthermore, plastic is one of the most complicated materials to recycle, in part, because consumers don’t know what types can be recycled and how. Below we explain the different types of plastics and their recyclability. A product made of plastic is stamped with a resin code, a number between 1 and 7 inside a triangle made of arrows (♺). Each number corresponds to a type of plastic and indicates its recyclability.
♳: PET/PETE (polyethylene terephthalate): a wrinkle-free fibre used to make beverage bottles and containers for various food items due to its strong ability to prevent oxygen from entering and spoiling the product; it is also able to keep the CO2 of carbonated drinks from escaping. This can be recycled.
♴: HDPE (high-density polyethylene): used to make bottles, such as milk jugs, cleaning product containers, and detergent bottles. This is the most commonly recycled plastic because it doesn't break under exposure to major heat or cold.
♵: PVC (polyvinyl chloride): a soft, flexible plastic used for many household products, such as pipes and flooring. This contains toxins harmful to health and the environment and is not recycled.
♶: LDPE (low-density polyethylene): used to make plastic wrappings, such as plastic bags, and can sometimes be recycled.
♷: PP (polypropylene): a stiffer plastic and is more resistant to heat. This is widely used for hot food containers, straws, bottle caps, and can sometimes be recycled.
♸: PS (polystyrene): used to make disposable styrofoam egg cartons, disposable cups, and packaging. This is lightweight and easy to form into plastic materials. This can sometimes be recycled.
♹: Other resins: a plastic that doesn’t fit into any of the 6 categories above and often made of multiple plastic types (e.g., acrylic, nylon, polycarbonate, polylactic acid). These aren't easy to recycle, unless exposed to high temperatures.
Environmental sustainability has increased in importance for people, environment, and industries universally. A sustainable environment promotes sustainable economic development.
The HYPPOS prototype has been successfully implemented on various plant types (e.g., HDPE) and the beta version has been successfully implemented on a PP plant.
HYPPOS & the circular economy
Circular economy (CE) is a non-linear model of production and consumption that involves reusing and recycling existing materials and products for as long as possible. CE is a deviation from the traditional, linear economic model (take ⇨ make ⇨ consume ⇨ trash). The following is a schematic of CE:
Consequently, the lifecycle of products is significantly extended. In essence, CE implies reducing waste to an absolute minimum. When a product reaches end of life, its materials are kept within the economy wherever possible. These materials can be productively used over again, thereby creating further value. CE relies on cheap, easily accessible materials, and energy.
How does HYPPOS fit into CE?
Carbon footprint reduction:
HYPPOS can reduce greenhouse gas emissions by up to 63,000,000 tons of CO2e per year, which is equivalent to 58 coal-fired plants or 50,237,860 cars driven for 1 year.*
Resource efficiencies:
HYPPOS can reduce resource usage, e.g., energy, water, and/or feedstock. Through waste reduction, plastic manufacturers can achieve savings of up to €25 million per plant, per year, due to improved efficiency in the production process, coupled with current and future compliance costs to the EU-ETS.*
HYPPOS contributes to CE by enabling the following:
HYPPOS enables waste reduction, recycling, renewable feedstock, and novelty.
(image & video credit: EU Parliament)
* A typical polymer plant with annual capacity of 300,000 tons.
HYPPOS Awards
We have received 4 renowned awards for HYPPOS: the Seal of Excellence from the European Innovation Council 3 times and a prestigious grant from the Cyprus Research & Innovation Foundation.
Seal of Excellence: June 2018, February 2019 & June 2019:
Opportunity/0916/SME-II Grant Award:
10 facts about HYPPOS
HYPPOS is an integrated, easy-to-configure, fast-to-install, highly compatible, decision support tool for use in continuous and semi-continuous production plants. Here are 10 facts about HYPPOS you may or may not know:
HYPPOS continuously collects data in real-time from plant instruments and feeds this data into its tracking model.
HYPPOS has a material tracking algorithm that uses real-time process values to track continuous movement of liquid, powder, and granular material by segmenting and characterizing material into discrete quantities.
A configurable workflow module, in HYPPOS, reacts to process events and data relating to a process, for example, interacting with the operators for batch production from initial batch creation through quality testing and packaging. This workflow module has the capability to interact with plant operators where defined processes require data, approval, or other forms of intervention.
HYPPOS boasts a modern web-based graphical user interface, which means that it is secure, platform-independent, and can be accessed 24/7. Users, allocated with appropriate permission rights, can collaborate easily either in one location or across various sites and geographies.
Using the innovative online analytical processing capabilities of HYPPOS, visibility is provided, quality issues can be identified and tracked in real-time. This allows for corrective actions earlier in the process, leading to improved product quality and less waste.
HYPPOS comes bundled with several pre-configured, built-in reports. Many more reports can be configured as per the customer’s needs and requirements, and deployed within HYPPOS.
HYPPOS provides seamless integration with various external systems, such as Open Platform Communications engines, Enterprise Resource Planning systems, and Laboratory Information Management Systems.
HYPPOS is an all-in-one deep tech decision support toolkit, whose deployment becomes faster and less costly.
HYPPOS tracks quality issues from the start, in real-time, which allows for corrective action earlier in the process and, therefore, more first time right polymer product. This means less energy consumption and CO2 emissions, transitioning to a sustainable manufacturing processes.
HYPPOS can reduce greenhouse gas emissions by up to 63,000,000 tons of CO2e per year, which is equivalent to 58 coal-fired plants or 50,237,860 cars driven for 1 year. Through waste reduction, plastics manufacturers can achieve savings of up to €25 million per plant, per year, due to improved efficiency in the production process, coupled with current and future compliance costs to the EU-ETS. A typical polymer plant with annual capacity of 300,000 tons.
The real-time reporting capabilities of HYPPOS
HYPPOS is an integrated, easy-to-configure, highly compatible, decision support tool for use in continuous and semi-continuous production plants.
A major part of quality assurance is to keep records of raw materials, process conditions, as well as analyses during each batch production. HYPPOS can easily feed its data, in real-time, to other management reporting systems or visualisation platforms. The above-mentioned data can be combined with data from various other sources (e.g., financial data and/or sales data from an ERP).
HYPPOS comes bundled with the following pre-configured reports:
Batch Summary Reports
Detailed Batch Reports
Additives Reports
Grade Daily Reports
Quality Reports
Scrap Details Reports
Production KPIs Reports
Production Quantity Reports
Detailed Production Reports
Many more reports can be configured as per a customer’s needs and requirements, and then deployed within HYPPOS.
HYPPOS' online quality processing capabilities
HYPPOS is an integrated, easy-to-configure, highly compatible, decision support tool for use in continuous and semi-continuous production plants.
In polymer manufacturing, even a small amount of off-spec material can impact batch quality. Lack of visibility of whether, when, and how such off-spec material is produced, and the inability to take corrective actions, can lead to loss of profits. Using the innovative online quality processing capabilities of HYPPOS, visibility is provided, quality issues can be identified and tracked in real-time.
Let's see how the online quality processing capabilities of HYPPOS work:
HYPPOS tracks discrete slices of material. Green slices represent in-spec material. Slices are continuously advancing through the equipment. Off-spec material, represented by a red slice, has entered the process. The batch silos, at the bottom, are being filled with in-spec material. Since the location of the off-spec material is known, it can be diverted from the in-spec batch silo to a different silo, thereby maintaining quality of the product batch.
The online quality processing capabilities of HYPPOS allow for corrective action earlier in the process and, therefore, more first time right polymer product (i.e., improved product quality and less waste). HYPPOS provides the means to reduce energy consumption, reduce carbon dioxide emissions, improve efficiency and, thereby, creating a positive impact on the environment.
HYPPOS, Industry 4.0, Digital Twins & Internet of Things
Industry 4.0 is a trend towards technological automation and data interchange within the manufacturing industry, that encompasses digital twins, the Internet of Things, and smart factories. This combination creates an ecosystem where machines, that incorporate sensors, enable production process visualization.
Digital twins are digital representations of real-world entities, such as devices, installations, and/or manufacturing production processes. These representations are created in the real world and linked, via the Internet of Things, allowing various systems to communicate and collaborate with each other in order to create combined, real-time data exchanges and automation. This automation includes connectivity between processes, data visibility, and support for decentralized decision-making.
HYPPOS is an integrated, highly compatible, decision support tool for use in continuous and semi-continuous production plants.
HYPPOS is an industry 4.0 product that enables digital transformation, allowing automated manufacturing via collaborative systems. This helps track processes and increase productivity. HYPPOS is based on the concept of digital twins as applied to the process manufacturing industry. The twin tracks material and quality data from production equipment and is synchronized using live values from the production process. HYPPOS combines digital twin data and other data in order to provide a view of the production process.
(image credit: Chair of cyber-physical systems in production engineering, Technical University of Munich)
HYPPOS helps reduce greenhouse gas emission compliance costs, improve efficiency & increase savings
HYPPOS is an integrated, easy-to-configure, highly compatible, decision support tool for use in continuous and semi-continuous production plants.
It comes with advanced material tracking capabilities, which lead to energy savings and waste reduction, whilst enabling improved quality and increased profitability of industrial polymer plants.
HYPPOS offers a solution that brings substantial cost efficiency to its bottom line (i.e., increased revenues by up to 1.5% and 25% reduction in equipment changeover time).
With the introduction of HYPPOS to polymer plants, compliance costs can be significantly reduced. Through waste reduction, plastic manufacturers can achieve savings of up to €25 million per plant, per year, due to improved efficiency in the production process, coupled with current and future compliance costs to the EU-ETS. HYPPOS is able to reduce greenhouse gas emissions of 63,000,000 tons of carbon dioxide equivalent per year, which is equivalent to 58 coal-fired plants or equivalent to 50,237,860 cars driven for one year.
Besides its superior functionality, HYPPOS' rapid deployment and delivery translates into a higher profit margins for our customers compared to solutions from other vendors.
The core team behind HYPPOS
HYPPOS is an integrated, easy-to-configure, fast-to-install, highly compatible, decision support tool for use in continuous and semi-continuous production plants.
HYPPOS combines 150+ person-years of deep industry experience.
Symeon Kassianides (BSc Chem. Eng., PhD Chem. Eng.) Hyperion Group Chairman & CEO, Executive Sponsor & Project Coordinator: 25+ years industry experience in oil & gas, and polymer & petrochemical operations management solutions.
Stavros Spanos (MSc Mech. Eng., MBA) Sales & Business Development Lead: 25+ years in sales & business development of software solutions & products to global process industries.
Daphne Demetriades-Colocassides (BA Econ., MSc Man. Sci.) Business Lead & Project Manager: 25+ years international ICT experience in digital project management, serial entrepreneur experience in tech-driven companies.
Symon Doe (Dipl. Elec. & Electro. Eng.) Software Architect: 35+ years experience in software architecture & development including industry 4.0 technologies in the polymer industry.
Sophia Louloudi (MSc. Chem. Eng., MSc Biochem. Eng., PhD, CFDs) Quality Assurance Manager: 15+ years experience in design, development, QA & integration of solutions in the polymers industry.
Sanja Jovanovic-Micunovic (BSc Mech. Eng., MSc Mech. Eng.) Technical Lead: 20+ years experience in MES software development & technical leadership in many polymer projects.
Learn more about the HYPPOS team members here.
"Our team has worked together for many years and we all share the same enthusiasm of seeing HYPPOS in the IT landscape of every process plant. The combination of expertise, motivation, and honest trust in HYPPOS' success is what we believe brings HYPPOS to a higher level."
— Sanja Jovanovic-Micunovic, HYPPOS Technical Lead
"We are challenged. We are excited that we have developed a product for the plastics industry that can have such a profound environmental impact throughout the world."
— Daphne Demetriades-Colocassides, HYPPOS Business Lead
HYPPOS offers an intuitive UI/UX with high quality & scalable vector graphics
HYPPOS is an integrated, easy-to-configure, fast-to-install, highly compatible, decision support tool for use in continuous and semi-continuous production plants.
A great deal of thought and effort has gone into designing the fresh and intuitive user interface (UI) of HYPPOS. And it shows!
HYPPOS boasts a modern, web-based, lightweight, graphical user interface that is both secure and platform-independent. End-users that are allocated with appropriate permission rights and privileges can collaborate easily as part of a team within a plant, either in one location or spread across various sites and geographies.
The web-based HYPPOS user interface makes use of familiar controls and navigational components that allow for effortless learning so as to get end-users up and running in no time at all. All relevant data is always readily accessible to end-users. HYPPOS provides data input validation for all of its input fields in order to ensure data integrity.
Several elements of the HYPPOS web user interface (i.e., colors and logos) are fully customizable. In this way, HYPPOS can accommodate the overall corporate identity of any plant.
HYPPOS makes use of high quality vector graphics to display plant equipment. All graphics are scalable and customizable.
Moreover, HYPPOS is built in such a way so as to accommodate multiple languages.
All of the above elements combine to make HYPPOS a world-class toolkit.
About HYPPOS