Contact Us

From White Board to Successful Execution

When a large-scale dairy operation set out to expand across 100 square miles, the plan existed only in whiteboard sketches and diagrams. Disconnected legacy control systems made scaling even harder. SkyIO stepped in to turn the concept into a unified, PlantPAx-ready system.

CASE STUDY

Capabilities Demonstrated

The Client:
Large-scale Dairy Manufacturing Facility

View services
  • Front-End Engineering Design (FEED)
  • SCADA Layer Optimization
  • Custom P&ID Data Mapping
  • Distributed Control Architecture
  • 3D Piping Models
  • Turnkey Control Panel Fabrication

Challenge: A Massive Expansion

Our client planned a 100-square-mile facility expansion, but the vision existed only as whiteboard concepts and civil diagrams. Without formal engineering schematics, the team faced blind spots around spatial layouts and power requirements, all on a compressed timeline. Underneath it: a hodgepodge of disconnected legacy control systems that couldn’t scale with the site. They needed one partner to structure the process end to end.

Solution: A Clear Path Forward

SkyIO joined during front-end design with a simple plan and every discipline under one roof:

  • Define | Whiteboard sketches became formal P&IDs and floor plans to develop a panel plan and overall system architecture design.
  • Prove | Tight piping spaces were modeled in 3D, so errors were caught on screen, not in the field. Panel communications were tested in the shop so they worked in the field.
  • Build | One team handled electrical design, panel fabrication, intelligent MCCs and full system integration.
  • Program | A certified Rockwell PlantPAX system was developed to control the facility, including PLC, HMI, and Historian programming.
  • Commission | Configuration and check out of 1500 IO points as well as process testing of ten  sequencers and thirty unit modules.

Success: Running One Unified Plan

Today, our client operates on a single distributed platform powered by Rockwell Automation PlantPAx. Disconnected legecy software is gone and their team has the centralized visibility and data history to run what they built. This way, they keep growing without redrawing the map. 

Technologies

  • Rockwell PlantPAx
  • Intelligent Motor Control Centers (MCCs)
  • Automated Valves
  • Instrument on I/O Link
  • Ethernet I/P PLC Network

More Case Studies

  • Batch Process Automation, Food & Bev, IT-OT, MES

From Paper Logs to Real-Time Genealogy

To help a major global beverage producer overcome the limitations of manual, paper-based tracking, SkyIO implemented a specialized MES layer that unified the brewery's SAP, MES, and PCS 7 systems into a single, governed data flow. This transformation eliminated disconnected Excel sheets and handwritten logs, providing the manufacturer with 100% end-to-end material traceability and an AI-ready, orchestrated IT/OT environment.
Learn more
  • Consumer Goods, IT-OT

A Clearer View of Production: Turning Data Challenges into Operational Momentum

Rockline partnered with SkyIO to elevate production visibility and bring greater clarity to plant-floor operations. Through a secure, scalable data platform, they gained real-time insights and streamlined reporting — creating new opportunities for smarter decisions and continuous improvement. Discover how the right data foundation can unlock operational momentum.
Learn more
  • Batch Process Automation, Chemical, Industrial Control Systems, IT-OT

Enabling Remote Factory Acceptance Testing of an Automation System for a Specialty Chemicals Manufacturer

A specialty chemicals manufacturer needed to implement a new control system while social distancing during the COVID-19 pandemic. A new batch automation system enabled remote factory acceptance testing (FAT), reducing travel time and expenses.
Learn more
  • Batch Process Automation, Food & Bev, MES

OEE/Downtime Monitoring and Reporting System for a Food & Beverage Plant

A large food production company wanted to be able to compare production performance (OEE / downtime) across manufacturing plants to facilitate continuous improvement and monitor efficiency.
Learn more
  • Consumer Goods, Continuous Process Automation, Factory Automation

Manufacturing Support Equipment Upgrade to Improve Production Quality & Reduce Downtime

The quantity of dust at a consumer products client was impacting production quality and the downtime of the dust collector equipment was too high. The customer needed to replace their dust collectors for process and plant improvement.
Learn more
  • Automotive, Continuous Process Automation, Factory Automation, Industrial Control Systems, Industry, IT-OT, MES, Segment

Factory Automation – Assembly Line Capacity Expansion

Automotive vehicle manufacturer needed to expand their assembly line capacity without bringing the existing line down for any significant period of time.
Learn more

Let's Build Something Great Together

Empowering industries with innovative automation, data-driven insights, and seamless integration.

Contact Us