The Need
Our client, a global spice processing company was facing challenges due to manual monitoring of their disconnected systems in the process line.
They were struggling to maintain consistency in product quality, high wastages, need for re-processing, and overall inferior products with lower end-customer acceptance.
Impacts Delivered
- Implemented an automated data collection platform from different plants and production lines in real-time.
- Significantly reduction in wastages and need for re-processing, improving the product quality.
- The customer was able to generate an annual savings of over 20% on their operational cost.
Our Solution
Critical Parameters monitored
- Temperature
- Pressure
- Solvent Flow rate
- Feed rate
- Energy Consumption
- Humidity levels
- Pressure of vacuum
- Operation duration
Delpheon Gateway
- Delpheon gateway provided a reliable and rugged solution for field data collection and aggregation
- Gateway communicated with the PLC’s via OPC-UA
- The gateway also accepts RS 485 Modbus communication from energy meters
- Data is pushed to be stored into a warehouse
Components of the Solution
- WMS Interface to download relevant data for the orders to fulfilled
- Indoor location of Assets – BLE based location of asset of up to ~1 to 2m
- Path-planner (Auto-navigation) module – calculate the shortest path to collect all the items in the set of orders and based on indoor location of asset.
- Wearable smart-glass that guide visually and helps in hands free scanning of barcode and picking items
Data warehouse
- Raw data is transformed, aggregated and stored into warehouse tables.
- The data is stored in format required to enable easy retrieval, visualizations and reporting functions.
Delpheon Visualization Studio
- Delpheon visualization studio enables the visualizations and play around with data to derive meaningful and actionable insights
- User management and data management is provided in the visualization studio=
Tools & Technologies
- Delpheon IIoT Platform
- OPC-UA for Data interface between PLC and Gateway
- RS485 Modbus communication from energy meters
