A leading UK retailer, serving millions of customers through an extensive store network, set out to modernize aging infrastructure in its high-throughput distribution centers. Burdened by legacy equipment and unsupported software systems, the organization needed a reliable way to bridge communication gaps without replacing critical machinery.
By working with a UK-based system integrator who leveraged OmniServer and OPC Data Logger software applications from Software Toolbox, the retailer achieved real-time visibility, accurate data collection, and the ability to respond quickly to underperformance. The result: improved fulfillment quality, reduced freight waste, and smarter use of transport resources.
Challenge: Legacy Devices Created Data Silos and Operational Blind Spots
Operating 24/7, the retailer’s facilities process hundreds of thousands of totes annually through a complex mix of cranes, conveyors, barcode scanners, and volumetric weighing systems. However, many of these machines relied on outdated, proprietary communication protocols—some compatible only with obsolete Windows 2000 or XP operating systems.
This created significant operational challenges:
- Data silos and limited visibility into crane status and tote movement.
- High operational risk due to unsupported legacy platforms.
- Inefficiencies in order picking, leading to underfilled totes and higher freight costs.
- Lack of data to justify improvements in picker performance or shift-based productivity.
Solution: Reliable Data Integration Using OmniServer and OPC Data Logger
The system integrator, an experienced provider of intelligent automated solutions for manufacturing, warehousing, and distribution, implemented the solution. With a global presence and deep supply chain expertise, they specialize in optimizing intralogistics performance through innovative software and automation. Their team delivered a solution that bridged communications between older, proprietary devices and the retailer’s modern SCADA system—ensuring continuous visibility and data logging in a high-volume, 24/7 distribution environment.
To manage the legacy text-based communication protocols used by five mini-load cranes, the integrator’s senior visualization engineer used OmniServer to interpret the custom protocols and expose them as OPC DA tags for the SCADA system.
“By having OmniServer, we've been able to put that communication on an up-to-date version of an operating system,” said the engineer.
With built-in ASCII parsing support, OmniServer allowed the team to accurately filter and parse raw string data received from the cranes.
Each crane was assigned a unique IP address and its own protocol topic in OmniServer, simplifying segmentation and management. Once the protocol for one crane was defined, it could easily be adapted for the others.
“I'll be totally honest, I've used it quite a few projects and once you get it working, that's it. We've never had any problems. OmniServer works forever,” the engineer added.
In tandem, the team deployed OPC Data Logger to collect PLC data from KEPServerEX. These PLCs gather data from barcode scanners and volumetric weighing stations along the tote conveyor. The system triggered a log entry as each tote passed through, recording barcode, weight, and calculated volume into a SQL database.
This enabled the team to monitor tote fullness over time, by tote ID and shift, supporting performance evaluations and identifying underfilled totes.
“If a tote is underfilled or underweight, it gets kicked to a reject station for manual inspection—and all that data is tracked. If there’s a recurring issue, it prompts the management team to ask, "What’s going on here?" At the end of the day, every tote that makes it onto a truck is optimally filled—because with the cost of diesel, you want those lorries as full as they can be.”
The implementation eliminated the need for middleware or custom code, providing a scalable, future-ready integration approach for additional devices like high-speed sorters.
Results: Scalable, Sustainable Modernization
- 778,000+ totes tracked annually at a single site, with barcode, weight, and fill percentage data logged.
- Zero downtime or support issues across multiple OmniServer deployments for over 10 years of non-stop operation.
- Enhanced picker accountability through per-shift reporting on tote fill quality.
- Seamless migration of crane communication to modern Windows Server OS (2019/2022), reducing IT, security, and operational uptime risk.
Why Software Toolbox?
The dependability and adaptability of its solutions have made Software Toolbox a reliable partner in critical automation projects. OmniServer enabled robust communication with non-standard equipment lacking native drivers, while OPC Data Logger delivered data, stored in standardized SQL Database, providing detailed data sets ready for analysis and reporting—all without disrupting operations.
Want to Modernize Your Access to Legacy Equipment Data Without Headaches?
If you're facing similar challenges with aging infrastructure, unsupported protocols, or fragmented and siloed data across your operations, our team is here to help. Schedule a consultation with our subject matter experts to explore how Software Toolbox solutions like OmniServer and OPC Data Logger can simplify integration, boost visibility, and future-proof your operations—without costly rip-and-replace projects. Book your consultation today.
About the End User
This project supports one of the largest UK-based retailers, with distribution centers moving millions of items weekly across the country. Today, their UK fulfillment centers depend on Software Toolbox’s OmniServer and OPC Data Logger to maintain reliable, efficient, and scalable warehouse operations.
