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In most of the industrial process plants, PI/PID controllers have been widely used because of its simple design, easy tuning, and operational advantages. However, the performance of these controllers degrades for the processes with long dead-time and variation in set-point. Up next, a PPI controller is designed based on the Smith predictor to handle dead-time processes by compensation technique, but it failed to achieve adequate performance in the presence of external noise, large disturbances, and higher-order systems. Furthermore, the model-based controllers structure is complex in nature and requires the exact model of the process with more tunable parameters. Therefore, in this research, a fractional-order predictive PI controller has been proposed for dead-time processes with added filtering abilities. The controller uses the dead-time compensation characteristics of the Smith predictor and the fractional-order controller's robustness nature. For the high peak overshoot, external noise, and disturbance problems, a new set-point and noise filtering technique is proposed, and later it is compared with different conventional methods. In servo and regulatory operations, the proposed controller and filtering techniques produced optimal performance. Multiple real-time industrial process models are simulated with long dead-time to evaluate the proposed technique's flexibility, set-point tracking, disturbance rejection, signal smoothing, and dead-time compensation capabilities.

Fractional-Order Predictive PI Controller for Dead-Time Processes With Set-Point and Noise Filtering