Software Toolbox Technical Blog

A major pharmaceutical company struggled with manual, error-prone data extraction for monthly compliance reporting within their utilities department. The team was reliant on fragile Excel macros pulling historical LGH file data from AVEVA InTouch HMI (formerly Wonderware InTouch) systems, which frequently broke due to Microsoft Office updates, causing costly delays and requiring repeated engineering intervention. 

To streamline their regulatory reporting process and ensure data accuracy and security, the pharmaceutical utilities group sought a robust, user-friendly solution to extract water and wastewater data efficiently without IT bottlenecks or operational downtime.

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.

How a Common Data Infrastructure is Helping Amcor Meet its Net Zero Goals

We are celebrating World Earth Day all month long and recognize that sustainability is not just about using eco-friendly materials — it is about making smarter choices in how we connect, operate, optimize, and innovate. To kick things off, this first blog of this year's Earth Day Series explores how Amcor, a global leader in the packaging industry, is leveraging TOP Server to drive efficiency, improve productivity, and help support its sustainability goals. 

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 The legacy setup relied on outdated communication methods, introducing inefficiencies and potential failure points.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.