Software Toolbox Technical Blog

A global beverage manufacturer sought to modernize its data workflows by integrating operational technology (OT) with enterprise systems. Specifically, they needed to transfer real-time data from their Rockwell Automation PLCs to their SAP system to automate workflows, enhance traceability, and streamline processes. The legacy setup relied on outdated communication methods, introducing inefficiencies and potential failure points. To overcome these challenges, the company required a robust, scalable, and future-ready solution.

This blog will give you an insight into how that solution became a reality and how they got there. Also, if you have not done so, please subscribe to our blogs to not miss out on similar topics.

If you're unfamiliar with Modular Procedural Automation (MPA), it helps automate start-up, shutdown and other data-driven procedures in a process, increasing efficiency, optimizing production, and reducing wear and tear on equipment.  Additionally, MPA helps increase operator productivity and confidence.

Adapted from the case study in Control Magazine, this blog post covers how Air Liquide, a world leader in chemicals manufacturing, is migrating to MPA using OPC UA and OPC bridging to lower startup time by over 60% and increase production to over 500 additional tons of liquid oxygen (LOX) resulting in increased profitability.

If you're unfamiliar with state based control, it's a process automation design that essentially defines that all process facilities should operate in a recognized, definable state with previously defined normal and abnormal conditions with defined actions for each.  State based control is intended to allow company's in virtually any process industry to greatly reduce factors of human error and inconsistency, significantly increasing the efficiency of all processes.

In this blog post, we cover how a large chemicals manufacturer migrated to state based control using OPC UA and increased their efficiency, production levels and profitability as a result.

Recently we worked with an aluminum smelter operation that has doubled in size since it first opened and has made a significant positive impact on the local economy by supplying aluminum to local industries which has fueled their growth.

Like any growing business, this user is always seeking ways to improve operations and reduce risk of downtime. In the end they need to deliver returns to their shareholders while continuing to support the local community, all of which requires consistent predictable operational results.  In this blog post, we'll cover how they used an off-the-shelf solution for integrating varied systems to reduce life cycle costs.

Earlier this year, we shared the story of how Namibia Breweries Ltd is using off-the-shelf open OPC software in their operations management system.  In that story, we shared how we had learned making beer in one of the world’s driest places takes some unique approaches to power sourcing, water management, and really all resources.

We visited with Namibia Brewing again recently when they attended the X-Change 2018 conference in the beautiful Central Drakensberg region of South Africa.   I had the chance to sit down with Annemarie Kruger, Renaldo Du Pisani, and Andre Engelbrecht and, in this blog post, you'll learn about how they have continued to evolve their system since I visited their site in 2017.

When you live in a remote region that is one of the most arid places on earth, you import your raw materials, and you’re making millions of hectoliters of beer a year, you have to make the most of all the resources you have and leverage what is in abundance in your location.  Namibia Breweries Ltd. (NBL) has a long history of success in a tough environment at their Windhoek site. They have received numerous awards for their innovative approaches to meeting their information system needs.

In this blog post, we’ll share their look into how they use off-the-shelf software and their teams' intellectual know-how and creativity to empower their manufacturing success.  If you read the stories in Automation World or Pro Food World you learned about how Andre Engelbrecht, manager of industrial control systems at NBL, and his teammates Annemarie Kruger, Rolando du Pisani and others unlocked data sources and built a digital smart manufacturing platform across the entire facility.  In this article, we’re going to share the rest of the story of NBL’s integration points, problems solved, and how they leveraged Software Toolbox’s full value proposition as part of their team effort.

There’s nothing like knowing that you aren’t alone, and someone else has had the same problems or successes that you have in similar situations.  That's just as true in the industrial automation world as it is in life.

This blog post will discuss how the peace of mind garnered from case studies and real-world examples when choosing a tunneling solution can be a deciding factor.