01 Material efficiency
20–25%
Fully autonomous machine control
Manufacturing
that adapts.
Automatically.
Dynamic feedstock. Self-correcting machinery.
VariControl continuously adapts machine settings to changing materials, corrects process drift and optimises production.
Feedstock changes. Control responds.
The potential, made measurable
Less waste.
More sellable output.
Turn better material, energy and machine performance into more value from the equipment you already own.
Read the CIRCULÉIRE case study02 Energy performance
Up to15%
Lower energy use per run
03 OEE & capacity
+5–15pts
Potential OEE improvement
Modelled opportunityMore output from the same machineMaterial and energy figures: company-reported pilot results, published by CIRCULÉIRE on 6 May 2026.
OEE · Turn performance into value
More output.
Same machines.
More sellable product.
Turn fewer rejects and more consistent cycles into more good parts ready for your customers.
Capacity you can unlock.
Recover lost production time and deliver more output from your existing machines.
Longer asset life.
Spot wear and process drift earlier to help protect machines, tooling and components.
Production line analysis
Measured baseline57.7%
Overall equipment effectiveness
Projected target63–73%
Approximate OEE after improvement
0%100% OEE
83.0% Availability70.1% Performance99.3% Quality
Illustrative annual opportunityPer machine.
€74k–155k
Per machine.
Per year.
More sellable output. More capacity from the machines you already own.
Explore your production scenarioMeet VariControl
Sense. Adapt. Self-correct.
Every production cycle.
VariControl closes the loop between material behaviour, machine settings and finished-part quality. A continuous cycle of sensing, autonomous adjustment and verification.
VariControl™Illustrative data
AUTONOMOUS CONTROL / CYCLE SIMULATION
New feedstock. A different process signature.
Cavity pressure724 bar
Reference range640–680 bar
Control responseDrift detected
Cavity pressure · bar
ObservedReference
The material changes. VariControl detects the shift.
A change in material behaviour triggers the autonomous control loop.
Interactive control simulation
The story in motion · 52 seconds
From material.
To intelligence.
Every shot carries a signal. Discover the thinking behind VariControl, from the material entering your machine to the intelligence controlling your process.
Originally shared on LinkedInRead the film’s key messages
The film follows material as it becomes a production signal, then an evolving pattern of intelligence. Its central messages: “It starts with material”; “Heat, pressure, flow — thousands of variables, every cycle”; “VariControl turns each shot into a live signal”; and “Intelligence, assembled in real time”. It closes with the VariControl and Mesh identities, and the ambition to predict, optimise and prove.
Intelligence at the machine
Changing materials.
Adaptive machines.
Consistent output.
Virgin, recycled and bio-based feedstock bring different behaviours to the machine. VariControl connects material intelligence with autonomous process control to keep production moving towards your quality and efficiency targets.
Find your starting pointDynamic feedstock control
Adapt to shifts in material behaviour and blend composition through continuous, automatic machine adjustment.
Asset life & uptime
Detect and correct process drift while tracking developing wear to support longer machine, tooling and component life.
OEE & productive capacity
Recover lost production time and improve consistency to make more sellable parts on the machines you already own.
Built around your process.
Focused on your performance.
Focused on your performance.
One autonomous control layer.
For the equipment you already own.
A practical path to value
Connect your line.
Close the control loop.
Bring autonomous control into your operation, with a clear integration scope, agreed operating limits and outcomes measured on your line.
Define your targets
Align on your process, available data and the outcomes that matter: quality, waste, energy or cycle performance.
A shared success baselineConnect the machine
Bring material records and process signals into VariControl and map the settings that govern your production.
A connected control layerActivate dynamic control
Configure your operating limits and enable automatic adjustments against your quality and production targets.
A continuous control loopOptimise and expand
Measure the impact on sellable output, OEE and resource use, then extend autonomous control across your operation.
More value across your operationHave a production challenge in mind?
Let’s connect autonomous control to your production goals.
Make the business case
Find the value
in your factory.
Explore less waste or more productive capacity. Build a scenario around your operation, then get your personalised estimate by work email.
Your personalised business case
The opportunity
starts with
your numbers.
Verify your work email to unlock your estimate. We’ll send a copy from info@meshbioplastics.com, with your assumptions and a clear breakdown.
01 Annual opportunity02 Your assumptions03 ROI with your costs
Checking email availability…
Discuss your business caseYour potential opportunityEmail verified
Estimated gross annual savings
—
First-year ROI—
Implementation payback—
Where the value comes from
- Material savings
- —
- Energy savings
- —
- Recovered productive hours / year
- —
- OEE improvement
- —
- Gross annual opportunity
- —
- Annual recurring costs
- —
- One-off implementation
- —
- First-year net benefit
- —
Net annual benefit after year one—
Let’s validate your business case
How the calculation works
Material & energy scenario: material savings = machines × annual material spend per machine × current scrap rate × relative scrap reduction. Energy savings = machines × annual energy spend per machine × energy reduction. These are added within this scenario only. Use net material losses after reuse and recovery credits. Output, prices and tariffs are assumed constant.
Production performance scenario: additional productive hours = machines × annual scheduled hours per machine × (target OEE − current OEE) ÷ 100. Annual capacity value = additional productive hours × your value per productive hour. Use incremental contribution after variable costs, not sales revenue. This is a simple OEE capacity model; it is not the downtime-recovery model behind the €74k–€155k opportunity above. Demand, staffing and downstream capacity must support the extra output.
No double counting: these are alternative business cases. Production performance value is never added to material or energy savings. OEE already includes quality and performance effects.
Your investment: first-year net benefit = the selected scenario’s gross annual opportunity − your annual recurring costs − your one-off implementation costs. Both costs cover the whole project. ROI = first-year net benefit ÷ first-year investment × 100. Costs start blank and come only from you. Both are required for ROI and net benefit; enter zero explicitly where appropriate. ROI is undefined for zero total investment.
Implementation payback: one-off implementation ÷ net monthly opportunity after recurring costs. It assumes steady benefits and costs, with immediate full benefit; it is not a cash-flow forecast. Positive implementation cost is not paid back if annual opportunity does not exceed recurring costs. For the OEE scenario, the capacity value must actually be realised.
Material and energy presets are illustrative; the higher preset uses upper figures reported in the CIRCULÉIRE case study. The OEE example starts from one measured baseline and a modelled target; scheduled hours and hourly value are editable assumptions. No outcome is guaranteed. Estimates exclude VAT, financing, tax and discounting.
The people behind the platform
Manufacturing experience.
Intelligence with purpose.
Created by Mesh Bioplastics in Limerick, Ireland. Bringing factory-floor experience, AI engineering and commercial leadership to a shared challenge.
Co-founder & CEO
15+ years in plastics manufacturing and commercial execution.
Co-founder & CTO
20+ years in AI and SaaS architecture, building enterprise platforms.
Tony Hannan
Co-founder & COO
30+ years in manufacturing quality systems and operational turnarounds.
Co-founder & CFO
25+ years in financial strategy and capital structuring.
Part of Ireland’s circular innovation communityCIRCULÉIRE 2025 Venture Accelerator ↗
Building the next chapter of industrial AI.
Investor enquiriesBuild what comes next
Great minds.
Real-world impact.
Bring your curiosity to a problem worth solving. We’re interested in people who connect bold ideas with practical engineering and better manufacturing.
Join the Mesh talent pool Share your CV and interests through Mesh’s recruitment form.Where could you make a difference?
Future opportunities- 01AI engineering
- 02Data science
- 03Software development
- 04Electrical engineering
- 05Material sciences
- 06Sales & business development
These are areas of interest for future opportunities. We’ll consider your experience as our team grows.
Let’s make better, together
For manufacturers, technology partners
and investors building what comes next.