Consulting for the Process Industry

Chemical companies in Germany are under sustained pressure from high energy and site costs, weaker demand, as well as increasing decarbonization requirements and growing regulatory burdens. Declining volumes are leading to rising unit costs and higher capital tied up, while service, quality, and safety are non-negotiable. At the same time, competitive pressure from China is increasing: Europe’s share of the global chemical market has steadily declined in recent years, while China has gained significant ground. In standardized basic chemicals, specifications are often more comparable. In more complex specialty and fine chemicals segments, Europe remains ahead in many cases, but the innovation gap is likely to narrow over the long term.

Horn & Company supports clients with comprehensive programs to improve cash flow, costs, and service —ranging from rapid liquidity generation and making the cost base more flexible, to the long-term alignment of the footprint and asset network.

Pharmaceutical companies face increasing cost pressures alongside stringent compliance and supply requirements. Complex supply chains, tight lead times, and strict quality standards increase the planning and management workload in production and the supply chain.

Horn & Company supports companies in optimizing operating costs and capital tied up, as well as improving procurement and service management, particularly in the indirect sector. Success factors include clear service and compliance guidelines, data-driven transparency regarding costs and performance, and an implementation model that translates improvements into processes and roles.

Food manufacturers face the challenge of rising cost pressures for raw materials and energy, high quality standards, and volatile consumer trends. Due to the strong bargaining position of retailers, these rising costs cannot be passed on. Best-before dates and an increasing variety of product options add to the complexity of planning, production, and logistics.

Horn & Company supports manufacturers in lowering production costs, reducing inventory, improving forecast accuracy, and stabilizing planning and order processes without compromising service or quality. Key success factors include clear service level guidelines, consistent cost and process discipline, and an integrated management model for cash, costs, and delivery capability.

Mining companies operate in an environment characterized by high energy and operating costs, geopolitical risks, fluctuations in prices and sales volumes, and increasing ESG requirements. Performance is heavily dependent on asset availability, maintenance, and a stable supply chain for spare parts and services, often in remote regions.

Horn & Company supports companies in reducing total operating costs, optimizing maintenance and materials management, and improving procurement and supplier management to enhance availability and reduce costs. Key success factors include a robust asset and maintenance setup, clear control of inventory and lead times, and a focused procurement approach for critical services and MRO.

Rising energy prices, fluctuating demand, increasing environmental requirements, and intense international competition are putting pressure on the paper industry in Europe. High fixed costs, energy-intensive processes, and sensitive equipment make capacity utilization, OEE, and maintenance key drivers of profitability.

Horn & Company supports clients in reducing manufacturing costs, improving equipment performance, and lowering capital tied up in assets, complemented by procurement levers — particularly for indirect materials, outsourced services, and maintenance. Success factors include clear service level guidelines for quality and delivery capability, consistent process and cost control, and a program approach that combines rapid cash flow improvements with sustainable cost savings.

Utilities play a vital role in the value chain of the process industry, as electricity, gas, steam, water, and grid services provide the foundation for stable production. In Germany, the landscape has undergone a structural shift in recent years: the loss of Russian pipeline gas has permanently altered procurement and pricing risks. Additional disruptions to global energy supply chains, such as those around the Strait of Hormuz, are increasing volatility and supply risks.

Horn & Company helps establish reliable supply as a firm foundation while simultaneously improving operating costs, cash flow, and process quality: from asset and maintenance management to end-to-end processes such as metering, billing, and receivables management.