Libra Speciality Chemicals, a high-growth SME and key supplier to global FMCG brands, needed to act faster, identify issues earlier and gain sharper control over its manufacturing operations. With growing complexity and rising customer expectations, manual methods were no longer enough.
In response, Libra partnered with XpertRule to implement XpertFactory, a decision-intelligence powered platform that now gives teams real-time visibility across every stage of production, boosting efficiency, improving quality and transforming decision-making.
The Challenge
Despite having a reputation for quality and innovation, Libra faced mounting challenges due to limited real-time visibility in its processes. Relying on manual recordings, engineers could only see issues while physically present, and managers were often making decisions based on outdated data. This approach caused delays, inefficiencies, and missed opportunities for improvement. As production demands increased, the need for timely, accurate data became critical.
For Libra, digital transformation wasn’t about disruption, it was about enhancing what works. The turning point came with Project ARGUS, an industry initiative backed 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.
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.
Libra served as the manufacturing testbed, piloting new optical sensors that detect microbial biofilms in real time, critical for preventing contamination and costly downtime.
To bring this data to life, XpertFactory provided the digital layer, capturing sensor outputs, triggering alerts, and offering actionable insights. It enabled teams to act before problems escalated. The success of ARGUS proved the value of live operational visibility, prompting Libra to expand XpertFactory across its core processes.
Dr Oliver Smith, Technical Manager at Libra Speciality Chemicals, commented, “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. “It’s created a culture of visibility and transparency and everyone’s now pulling in the same direction.”
Real-Time Intelligence, Plant-Wide
One of the first expansions focused on monitoring tank levels, previously a manual and fragmented process. With XpertFactory, data is now digitised, visualised, and shared through intelligent dashboards. Teams across procurement, sales, and supply chain all work from the same real-time data, reducing delays, miscommunication, and duplicated effort.
Live monitoring of agitator speeds, temperature, and power use has unlocked even greater benefits. Trends are tracked across batches, giving early warning on inefficiencies. “If a process takes longer than expected, we know immediately,” explains Oliver, Libra’s Site Manager. “That helps us investigate and adjust without waiting for end-of-week reviews.”
Beyond technology, XpertFactory has driven a powerful cultural change. Teams now collaborate with confidence, 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. Urgent customer requests are handled faster. Decisions are grounded in evidence, not assumptions. “When a customer has an urgent request, our teams can check the status and respond quickly,” says Sahd Hussain, Commercial Director. “We’ve reduced delays and miscommunication because people no longer need to check updates; they just check the system,” he concluded.
Looking Ahead..
With tangible gains in quality, consistency, and efficiency, Libra is now extending XpertFactory’s reach, starting with eliminating paper trails. Upcoming developments include digital sign-offs and automated compliance logs to improve traceability and simplify audits, critical in a regulated industry.
Darren Falconer, XpertRule Technical Director says, “With XpertFactory, Libra has transformed its manufacturing operations from manual and reactive to real-time, intelligent and highly efficient. Operating from the same live data, enables cross-functional collaboration and faster, more confident decision-making.”
He adds, “ultimately, XpertFactory is not only meeting Libra’s current operational demands but actively shaping best practices for the future.”
Crucially, the journey has been collaborative. “XpertRule listens. They don’t just offer a tool, they offer a partnership,” says Oliver. “It’s not off-the-shelf; it’s something that evolves with us,” adds Sahd.
Libra Speciality Chemicals continues to lead through quality, innovation, and service, now powered by a smarter, data-driven approach to manufacturing. With XpertFactory, they’ve turned digital transformation into measurable business impact.
To learn more, visit Responsible AI | Case Study
