Client challenge
Each of the facility's four lines ran its own standalone HMI with no shared historian, making cross-line trend analysis and centralized alarm response impossible for the control room.
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Plant-Wide SCADA Consolidation for a Multi-Line Beverage Facility
Realistic sample engagement: consolidated four independently monitored blending and filling lines into a single plant-wide SCADA system with unified historian and alarm management.
Rockwell Automation
4
Lines consolidated
0 hrs
Unplanned downtime during cutover
−38%
Alarm count
Proposed solution
Designed and deployed a redundant FactoryTalk SE SCADA architecture polling all four lines, with a unified alarm philosophy and a consolidated historian for plant-wide reporting.
Implementation process
- 01Network and architecture assessment across all four lines
- 02SCADA server and redundancy design
- 03Alarm rationalization workshop with operations
- 04Phased line-by-line cutover with zero unplanned downtime
- 05Operator training and go-live support
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