Vernaio

Vernaio is a Munich-based AI company helping manufacturers in the process industry reduce production costs — by lowering energy and raw material consumption while maintaining stable output and quality. Many industrial lines run with conservative process settings. Understandably so — quality must be secured, and process conditions are complex. But this often leads to unnecessary energy use and excess raw material consumption. Losses that quietly reduce margins — day by day. What we do at Vernaio Our AI-based copilot helps manufacturers operate closer to the true process optimum — by safely exploiting process limits. It analyses historical process behavior and learns real cause–effect relationships from existing raw data, with minimal expert input. Powered by our unique Causal AI technology, it develops a deep, line-specific understanding and integrates seamlessly into day-to-day operations. The result A tailored production copilot that supports your team in real time — with precise set point recommendations that reduce energy and raw material consumption, while maintaining quality and output. Typical effects - Lower energy consumption - Reduced raw material usage - More stable, predictable runs - Lower CO₂ emissions as a direct result of improved resource efficiency Implementation facts - Feasibility analysis based on historical data:~2 weeks - First line live:~3 months - No major IT/OT changes required - ROI within the first year Already in use in- Nonwovens - Papermaking - Gelatine - Heated Tobacco - Converting