Real-Time, Real Value

The opportunity to change that came through Project ARGUS – a cross-industry initiative supported by Made Smarter and led by Procter & Gamble. The goal was to reduce the time and disruption caused by microbial contamination – a common but costly issue for chemical manufacturers.

A build-up of microbes in production equipment often means deep cleaning or downtime. In worst-case scenarios, contamination can lead to product recalls, damaging consumer trust. To mitigate this, rigorous testing is carried out at each stage of the supply chain. But traditional methods require samples to be incubated for up to three days, delaying production and tying up revenue in quarantined stock.

Project ARGUS set out to solve this bottleneck using the latest optical sensors to detect microbial biofilms in real time, either on surfaces or in flowing liquids as product moves through the lines. The UK supply chain of Fairy Liquid served as a case study, with Libra providing the real-world production environment.

XpertFactory – XpertRule’s Decision-Intelligence powered manufacturing solution – provided the digital layer, capturing real-time sensor data and visualising contamination risks as they emerged, not days later. This early-warning capability, supported by intelligent decision-powered alerts, enabled swift intervention before issues could escalate, helping prevent unnecessary downtime.

With the value of XpertFactory clearly demonstrated, Libra saw an opportunity to use real-time data across its site to improve performance, not just hygiene.

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Improved Oversight, Fewer Delays

Libra’s next step was to expand live visibility into its core operations. One of the first applications was monitoring tank levels. Like many manufacturers, Libra’s monitoring processes were largely analogue. Knowing the status of a batch or vessel often meant walking the plant floor or tracking down colleagues.

That data is now captured digitally and automatically pulled into a live intelligent dashboard with decision-powered alerts. Procurement knows when to reorder. Sales can check product readiness. Supply chain teams can plan dispatch. Instead of relying on verbal updates or physical checks, every team now works from the same live data, accessible in seconds and automatically notified on change. This connected view of operations has reduced delays, eliminated duplicated effort and decisions are made without the guesswork.

Crucially for Oliver and his team, it has created space for continuous improvement, proactive monitoring, predictive insights and intelligent data-driven decisions.

“Having centralised, real-time visibility has transformed how the site operates. Instead of reacting to problems, we anticipate and plan around them based on accurate, up-to-date information.”

Dr Oliver Smith, Technical Manager

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Actionable Insight That Drives Performance

By monitoring live production metrics like agitator speeds, temperature profiles and power consumption, Libra can now track trends across batches and identify where small changes can unlock measurable gains.

“If a process takes longer than expected, we know immediately,” Oliver says. “That helps us to investigate, adjust and improve without waiting for the next review cycle. It’s also helping us build more accurate cost models by improving our pricing, margins and energy efficiency.”

With XpertFactory, changes are backed by evidence, helping teams prioritise actions that deliver the greatest impact. From improving batch consistency and optimising reactions to reducing cycle time, the site is now driven by data.

One of the biggest outcomes has been cultural. Teams across the business can now make decisions with confidence because they’re all working from the same data.

“When a customer has an urgent request, our teams can check the status and respond quickly,” says Sahd. “We’ve reduced delays and miscommunication because people no longer need to check updates; they just check the system.”

That transparency supports cross-functional collaboration and ensures accountability, while freeing teams up to focus on solving problems rather than tracking them down.

“It’s created a culture of visibility and transparency, everyone’s pulling in the same direction.”

Dr Oliver Smith, Technical Manager

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Ready for What's Next

Libra is now looking to extend its use of XpertFactory, starting with eliminating paper trails.

Digital sign-off and automated compliance logs are now in development, creating a tamper-proof system to enhance traceability and simplify audits – critical requirements in regulated industries like chemical manufacturing. “The goal is to manage the entire process digitally, end-to-end,” Sahd says.

Reflecting on the progress so far, both leaders are quick to credit the platform’s adaptability and the support given. “The XpertRule team has been fantastic,” says Oliver. “When we have a suggestion, they listen. When there’s an issue, they help solve it. It feels like a partnership, not just a technology solution.”

“XpertFactory isn’t an off-the-shelf solution you’re forced to adapt to,” Sahd adds. “It’s a system that grows with your business and your needs,”

Libra Speciality Chemicals continues to lead with quality, innovation and customer service – now with sharper tools to support that commitment.

“We’ve gone from gut feel to data-driven. That changes everything. How you operate. How you plan. And how you grow. It means fewer delays, better planning, stronger compliance and, ultimately, better outcomes for our customers.”

Sahd Hussain, Engineering and Process Safety Manager