This manufacturer was ready to invest in performance but lacked the infrastructure to support it. Their new mixer represented a leap forward in capability — but their control system was holding them back.

Precision was limited, manual control caused inconsistencies, and they faced serious risk launching a major upgrade without simulation or system standardization. The team knew that if this wasn’t done right, it could cause costly downtime, rework, and production delays.

• Outdated PLCs could not communicate reliably with the new mixer

• There was no centralized SCADA system for visibility or device coordination

• In-house resources lacked capacity to standardize and simulate a full upgrade

• Risk of errors or downtime during commissioning was high

• 🔄 Upgraded the plant’s control backbone to the latest Rockwell PLC platform

• 🧭 Created detailed P&ID diagrams to guide the new control system design

• 🧠 Developed a new PLC logic standard to support long-term scalability

• 🧪 Built a simulation environment to fully test control logic before live production

• 🌐 Deployed Ignition SCADA with real-time dashboards and device-level control

• 🔗 Fully integrated the new German mixer with seamless communication

• 🛠️ Provided VFD tuning, real-time troubleshooting, and commissioning support

• 🧑‍💻 Ongoing post-commissioning assistance to ensure smooth performance

Post-upgrade, the client now runs a tightly integrated, modern control environment that provides real-time visibility, deep analytics, and confident precision across the mixing process. The new Rockwell PLC system delivers stable, repeatable logic, while Ignition SCADA gives plant managers and engineers full insight and control.

With simulation-based validation and hands-on commissioning support from Innorobix, the entire deployment went live without disruption, and the operations team is now equipped with a scalable, high-performance control system that sets the stage for future automation initiatives.