Process optimisation is often a multi-criteria problem. Combined with the use of nonlinear models, generating a Pareto front can be difficult to achieve reliably. This paper describes the use of high-dimensional data analysis and visualisation techniques as the basis for a multi-step procedure for generating a Pareto front for a two criteria problem. A case study in process design is used to illustrate the procedure. The results show that the use of data analysis and visualisation can help gain insight into the Pareto optimal solutions or confirm the insight the engineer already has. (c) 2006 Elsevier Ltd. All rights reserved.