Welcome to A Inverse
Process Control & Automation for Steel and Manufacturing
Engineers who model the process, design the controls and panels, and work on your plant floor — with deep roots in steel and metals processing.
100+
Years Combined Experience
Ph.D.
Process Modeling Expertise
20+
Founder's Years in Metals
24/7
On-Call Support Agreements
Our Approach
How We Engineer Solutions
Signal flows from raw data through physics-based models and control algorithms to precise real-world actuation, with continuous feedback ensuring optimal performance.
MATLAB / Simulink
Process and drive models
Pre-Commissioning Sim
Validate before deploy
Digital Twin
Dynamic process simulator
Operator Practice
On the simulator first
Why A-Inverse
Engineering That Moves Production
Based in Northwest Indiana, serving steel mills and manufacturers nationwide with engineering grounded in the physics of your process.
Reduce Downtime
Root-cause investigations and on-call support that get equipment back into production.
Find the Bottleneck
Physics-based models built to show what limits tons per hour for each product.
Trust Your Data
Analysis that separates real process changes from instrument drift.
Modernize Legacy Systems
Migrations from aging PLC and SCADA platforms to current systems, starting with a proof of concept before the full conversion.
Our Mission
Transforming Complex Systems Into Elegant Solutions
A-Inverse delivers cutting-edge technology and advanced engineering solutions to the manufacturing sector. We combine first-principles physics with modern modeling techniques to solve the hardest industrial challenges.
Based in Crown Point, IN, we serve clients nationwide — mostly in steel and metals processing, with work in food production, marine, and general manufacturing.
Physics-Based Modeling & Simulation
Systems Identification & Optimization
Real-Time Control Implementation
24/7 On-Call Support Agreements
What We Do
Engineering Services
Process simulation and operations modeling, control systems, panel design and supply, automation programming, motor control, and on-site engineering.
Process Simulation
First-principles physics models — thermodynamics, fluid dynamics, and material science — built from the ground up.
Control System Design
From PID to model-predictive control: robust architectures tuned, tested, and validated for your specific process.
Panel Design & Supply
Engineered control panels built by fabrication partners to our designs, plus automation hardware supply.
Automation Programming
ControlLogix and Ignition, including PLC-5 to ControlLogix and iFIX to Ignition migration work.
Motor Control
Drive selection, VFD tuning, motor sizing, and advanced torque-control strategies for high-performance lines.
On-Site Engineering
Consultants, engineers, and technicians at your plant, from single call-outs to ongoing engineering support.
Mill Models
Physics Models for Steel Operations
First-principles models of your production units, built for offline analysis by operations, R&D, and engineering teams — to find bottlenecks, test what-ifs, and support capital decisions without touching production.
Explore Mill Models- Hot strip mill finishing-mill capability and throughputIn development
- Furnace pacing for furnace-limited products In development
- Cold mill setup and productivityIn development
- Hot and cold mill as one continuous unitOffered as a study
Industries
Sectors We Serve
Steel and metals processing first — with projects in food production, marine, and general manufacturing.
Hot & Cold Rolling
- Mill and drive modeling
- Strip-break analysis
- Model audits
Reheat Furnaces
- Level 2 model tuning
- Pacing and throughput
- Combustion and NOx
Power & Steam
- Boiler control modernization
- Flare stack automation
- Gas pressure control
Casting
- Panel retrofits
- VFD upgrades
- PLC and drive support
Service Centers
- Leveler analysis
- Coil handling
- Drive replacements
Food & Marine
- Batch SCADA upgrades
- Drive panels
- Propulsion troubleshooting
Case Studies
Recent Projects
Real engineering problems from steel mills, food plants, and the field.
Cold Mill Start-Up Strip Breaks
Cold RollingChallenge
Repeated start-up strip breaks on light gauge after a main drive upgrade.
Solution
Mill data plus a Simulink stand and drive model pinpointed strip rollback at stop.
Root cause found; fix in plant trials
Reheat Furnace Engineering Support
Hot Strip MillChallenge
A hot strip mill needed more from its reheat furnaces and Level 2 control.
Solution
On-site engineering: pacing control, throughput forecasting, heat transfer, and combustion analysis.
Ongoing furnace improvement support
Naval Vessel Propulsion Trips
Marine & DefenseChallenge
Propulsion trips on a government marine vessel.
Solution
On-board troubleshooting of the propulsion power supply chain and thruster tests.
Trips traced to a power-supply fault
Batch SCADA Upgrade
Food ProductionChallenge
Batch production running on an aging iFix SCADA system.
Solution
Rebuilt the batch SCADA in Ignition and tested it before installation.
Batch control on a supported platform
Technology Stack
Automation Technologies
ControlLogix
Allen-Bradley PLC programming
Ignition
SCADA and HMI
AVEVA PI
Historian development and support
MATLAB / Simulink
Process and drive models
Model-Based Control Design
Process and drive models in MATLAB/Simulink that guide control changes before they reach the PLC.
Pre-Commissioning Simulation
Test control logic in closed loop against a dynamic process simulator before it reaches live equipment.
Legacy Migrations
PLC-5 to ControlLogix migrations that start with a proof-of-concept phase, and an iFIX to Ignition HMI upgrade commissioned on site.
Get Started
Ready to Optimize
Your Systems?
Located in Crown Point, IN — serving steel mills and manufacturers nationwide. Let's talk about what's limiting your line.