Change of the processing sectors toward a much more sustainable manufacturing model should guarantee continued growth and global competitiveness. Achieving this requires adopting unique reactor technologies, greener reactions and increase in smart system usage. A new task is developing new techniques and tools for modelling and control of reactor based procedures, based on real-time sensing and comments. This should facilitate developing a new paradigm of more intensive, low-impact and sustainable chemical technologies. The task is focused on the development of a new procedure control approach to improve process effectiveness through intensification of semi-batch and 'smart-scale' constant polymerisation procedures. This will be accomplished by connecting molecular-level information of the response chemistry with soft sensors, integrating rigorous mathematical models, and subsequently implementing reduced models for non-linear model-predictive control and powerful real-time optimization. After characterising various polymers and polymerisations, experts have produced and validated semi-batch and smart-scale designs for online control programs. Process intensification for polymerisation systems have actually been investigated in a smart-scale tubular reactor with static mixers. The outcomes, so far reveal feasibility and robustness of an established stable procedure with large solids content throughput. A further important success features been the development of sensor fusion whereby a soft sensor approach is being created to allow for the processing of a number of information at the same time such as temperature ﬂow, area acoustic trend, temperature and conductivity. Currently, efforts are in place to prepare for a successful demonstration of polymerisation processes at a production-pilot grow, thus placing developed theory from the lab scale to grow scale. Researchers have made significant improvements with regard to developing state-of-the-art model-based procedure control techniques with unique focus on improving item properties.