Increased globalisation and competition are drivers for process analytical technologies (PAT) that enable seamless process control, greater flexibility and cost efficiency in the process industries. This research is carried out in collaboration with a project which aims to introduce an integrated process control approach, embedding novel sensors for monitoring in real time the critical control parameters of key processes in the minerals, ceramics, non-ferrous metals, and chemical process industries. The paper will review the development of a suite of affordable sensors along with smart sensor features and algorithms for easier integration, easier maintenance, metrological performance enhancement, process monitoring and control and sensor fusion for use within this versatile global control platform implementing PAT. Smart sensors will be investigated that match existing offline solutions in performance while enabling size reductions, low power consumption, low unit costs, low maintenance costs and data fusion.