Synthomer
London-based multinational specialty chemicals company, Synthomer, produces additives and raw materials for creating coatings, paper, textiles, and health and protection products. Previously, the company’s production facility in Piedmont, Italy was controlled by PLCs from different manufacturers operating independently in siloes. These islands of automation were difficult and expensive to maintain and operate.
In 2018, Synthomer modernized the plant’s disparate monitor and control system with an ftServer running Rockwell Automation PlantPAx® DCS, including HMI/SCADA, with the help of system integrator, Progecta. The project drove a considerable increase in production and revenue at the plant by creating a simple, standardized, and resilient system.
“Redundancy at the compute level matched with PlantPAx DCS redundancy at the control level, is a formidable combination for downtime prevention for mission-critical applications. By partnering with Rockwell Automation to characterize this joint solution, we’re delivering a massive leap forward for operations.”
Challenges
- Centralize control of siloed PLC systems from different manufacturers
- Solve the expense and complexity of operating disparate PLCs
- Migrate to a distributed control system without shutting the plant down
Solutions
- Stratus ftServer deployed in the control room
- Rockwell Automation PlantPAx DCS
- System integration by Progecta
Benefits
- 99.999% uptime with the fault-tolerant ftServer
- Vast availability of data empowers operators and fuels analytics
- 30% increase in production at the Piedmont facility