Process and production optimization
The project involved the implementation of a digital production data acquisition (PDA) system for the production lines of confectionery manufacturer HOSTA in order to record and visualise production data. The aim was to use the insights gained to increase the efficiency and quality of production and realise energy savings.
Realisation
The task was realised by implementing a digital production data acquisition system (PDA) with state-of-the-art technology. Softing's "DataFEED OPC Suite" was used, which was installed on a central server to collect production data from PLC central units and weighing units on the production line. This data was recorded in real time via an OPC UA server and was available for live visualisation. In addition, the WIPOTEC software "Comscale4" was used to collect weighing and statistical data, which was integrated into the central system via a REST interface.
The entire architecture was based on a three-tier server solution: Data acquisition, data processing and visualisation. The web-based visualisation was carried out via the atvise® platform, which enabled a platform-independent view of the production data. This allowed operators and production management to monitor production processes in real time, detect errors more quickly and initiate optimisation measures immediately. Of particular interest to a specialist audience is the use of modern technologies such as OPC UA and REST APIs, which enable the seamless integration of different data sources and systems and therefore offer a high degree of flexibility and scalability.
Customer benefits
The main customer benefit of this project was the significant improvement in production processes and the increase in efficiency. By introducing digital production data acquisition (PDA), HOSTA was able to access key production figures in real time, enabling transparent monitoring and control of the production lines. This led to better product quality, as sources of error could be recognised and rectified more quickly. They also benefited from higher plant availability, simplified maintenance planning and a reduction in energy consumption and production waste.
In the long term, the HOSTA system made it possible to collect and analyse production-critical data, which not only increased efficiency but also contributed to sustainable and cost-efficient production. This strengthened competitiveness and increased customer satisfaction through improved product quality and optimised production processes.
