2015

Trends in
Technology

Process industry manufacturers and OEMs face the same challenges theyve
battled for years, but now theyre juggling new consumer demands driven
by busy lifestyles, millennials, baby boomers and mobile devices. Meanwhile,
IT and industrial automation technologies continue to merge, enabling the
Internet of Things, industrial Ethernet, remote access and other technologies to
support The Connected Enterprise and help companies in the packaging, food
and beverage, life sciences and other industries finish projects on time within
budget. See what technologies are helping them stay competitive.

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Table of contents
7 TRENDS IN TECHNOLOGY IN 2015

ARE YOU READY FOR THE CONVERGENCE OF IT AND OT?

AS INDUSTRIAL NETWORKS CONVERGE, SKILL SETS MUST BROADEN

Process manufacturers and OEMs face the same challenges theyve battled for years, but now
theyre juggling new consumer demands driven by busy lifestyles, millennials, baby boomers
and mobile devices. See what technologies are helping these companies stay competitive.

HOW KINGS HAWAIIAN CREATED A COMMON NETWORK INFRASTRUCTURE

15

FACILITATING FSMA COMPLIANCE WITH TECHNOLOGY

18

VIDEO: TYSON FOODS - HILLSHIRE BRANDS BOOSTS COMPLIANCE WITH

MANUFACTURING INTELLIGENCE SOFTWARE

19

THE RISE OF SERIALIZATION REGULATION: WHAT TO KNOW AND DO

22

VIDEO: SERIALIZATION LEADS TO OPTIMIZATION

24

OEM PROFILE: OEM HELPS CUSTOMERS BY USING CLOUD-BASED SOLUTION

25

ARE YOU MANAGING YOUR NETWORK SECURITY RISKS?

27

ADDITIONAL RESOURCES

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Learn how the popular bread-baking company standardized technology requirements for multiple
OEMs and eased integration and data sharing in a new facility.

The FDA set the food safety compliance objective, and leaves it up to you to figure out how to get there.
Here is some guidance on what you need.

A comprehensive and holistic pharmaceutical serialization system can offer significant benefits
beyond regulatory compliance.

Cloud-enabled remote monitoring solution allows Premier Tech Chronos to optimize machine
performance with deeper insight into equipment and diagnostic information.
Learn 10 steps to help protect control systems on a standard network, and find out what
Rockwell Automation network security solutions are designed to help.

AD INDEX
Rockwell Automation

14

the journals fundamental series webinars

30

ControlLogix, CompactLogix, PowerFlex, PlantPAx, PanelView, Stratix, Encompass, PartnerNetwork, FactoryTalk and RSLinx are trademarks of Rockwell Automation, Inc.

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7
Trends in Technology in 2015
XXXXXXXXXXXXXXXX

Process
industry manufacturers and OEMs face the same challenges theyve battled for years,
XXXXXXXXXXXXXXXXXXXXXXXXXXXX
but now theyre juggling new consumer demands driven by busy lifestyles, millennials, baby
boomers
and mobile devices. See what technologies are helping them stay competitive.
By XXXXXXXXXXXXXXX
By Theresa Houck, executive editor, The Journal from Rockwell Automation and Our PartnerNetwork

>>

Manufacturers and OEMs in the food and

beverage, household and personal care, life
sciences and other process industries deal with fluctuating
technology and consumer challenges on a daily basis. This
kind of stay-on-your-toes pressure means they depend as
much on information and control solutions as they do on
the equipment performance to achieve sophisticated levels
of integration, flexibility and productivity all while being expected to cut costs.
Of course, many of the dilemmas they face havent
changed, including new technologies, the need to minimize costs, end users who need more from their OEMs,
changing packaging styles that have a shorter life cycle,
environmentally-friendly packaging, and ever-changing
consumer desires. However, smartphones, urban dwellers,
millennials and even baby boomers are affecting
how process industries must operate. For example,
consumers want:
Smaller, portable, individual packages that are easy
to open especially children and older adults who might
be challenged with strength, dexterity or poor eyesight.
Packages with re-closable features so they can save
contents for later.
Packaging for the growing population of city
dwellers who often walk, use public transportation
and live in smaller spaces.
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Packaging thats attractive and durable for an on-the-go

lifestyle a trend often credited to the selfie generation
thats constantly being photographed.
Packaging that looks good on digital devices for
people who, especially millennials, now shop on their
smartphone.
This means manufacturers need equipment thats
flexible enough to handle a variety of product sizes and
incorporate quick changeover; that can adapt to changing packaging styles; and that can integrate control
and information technologies to enable secure remote
access, virtualization, analytics, the cloud, the Internet
of Things (IoT) and more. These technologies support
The Connected Enterprise, which offers huge potential
for OEMs and how they can support end users.

Converged Technologies

End users automation and information technology (IT)

functions now are converging to provide a more coordinated effort. As a result, OEMs are working toward
implementing manufacturing convergence both at
their own operations and for their end-user customers.
Thats why The Connected Enterprise is so important;
it supports the convergence of IT and operations
technology (OT).
Essentially, The Connected Enterprise allows
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How do you know if the

technology youre using and
the way in which you use it is
on par with your peers?

Remote Access for

Reduced Costs

The Connected Enterprise supports the trend

of increasing use of wirecollaboration among people, plant-floor systems and
less technologies, which is
enterprise applications to help improve productivity. It
important for remote access
provides access to real-time and historical data and all
between OEMs and end usof the business and transactional data that will affect
ers machines. As the value
different plants and their operations.
proposition for remote acEnd users will turn to OEMs that understand
Attitudes about remote access
cess continues be realized by
and provide equipment that enables machinery-toend users, more OEMs are
have changed from Im not sure
enterprise information flow, or Smart or Connected
viewing secure remote access
that we need it to How do we
Machines, says Mike Hannah, market development - do it? Adam Lindsey, global
as a competitive necessity to
The Connected Enterprise, business development manager,
provide for their end-user
Rockwell Automation.
customers.
Spectrum Controls
End users need machines
Attitudes about remote
that are increasingly realaccess have changed from, Im not sure that we need it to
izing the benefits of more
How do we do it? says Adam Lindsey, global business
information, insights and
development manager with Rockwell Automation Encomdata that can be offered to pass Product Partner Spectrum Controls.
the user to improve proFor example, Rockwell Automation OEM Partner
duction, perform proactive Pearson Packaging Systems considers secure remote access
maintenance and better
and remote monitoring to be an extension of its customer
End users will turn to OEMs
diagnose and prognosticate service process and machine/system installation process.
issues.
Our controls engineers have found remote access to be
that understand and provide
So, how do you know
particularly helpful during system installations with the
equipment that enables machinif the technology youre
ability to make programming modifications from their
ery-to-enterprise information
using and the way in
offices while working with on-site personnel, explains
flow, or Smart or Connected
which you use it is on par
Eric Pritima, product manager with Pearson Packaging.
Machines. Mike Hannah,
with your peers? To help
On the service side, if we can quickly resolve an issue or
market development - The
you find out, lets take a
problem remotely without the time and expense of a serConnected Enterprise, Rockwell
look at the 2015 top trends vice visit, thats a win for both the customer and Pearson.
Automation
in technology that affect
He says eliminating just one on-site service call during the
food, beverage, household and personal care, life scilife of the machine can return the customers investment
ences and other process industries.
in the remote access option.
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Remote monitoring can help improve uptime and

fill knowledge gaps, according to Sal Conti, remote
monitoring product manager at Rockwell Automation.
Many manufacturers are dealing with leaner budgets,
aging workforces, and increasingly distant and disparate production facilities. Making your most qualified
engineers available to any production site, at any time
would seem to defy logic, he says.
Clearly, users require a remote access solution thats
better suited to their industrial requirements, rather
than products adapted from consumer or commercial
one size fits all solutions.
Rockwell Automation Encompass Product Partner
ProSoft Technology develops protocol interfaces, wireless radios and other communication solutions compatible with Rockwell Automation to provide connectivity
between automation products as seamlessly as if they
were all from the same supplier. One of its functions is
to help OEMs who go outside Rockwell Automation
protocols and need C/C++ coprocessors and wireless
solutions for a secure, reliable network connection.
One of the things we do is work with OEMs to
help them get connectivity with customer machines
using a Rockwell Automation architecture even if a
device isnt available on EtherNet/IP, Device/Net,
ControlNet or some other network, explains Ken
Roslan, vice president, Global Marketing for ProSoft
Technology. If the OEM needs to do something in
their machine thats not based on standard product, we
work with them for a custom-designed solution.
Thats exactly whats happening through the
emerging use of remote monitoring. Two factors are
driving this: The convergence of OT and IT systems
into The Connected Enterprise, and the adoption of
new enabling technologies, such as the IoT and cloud
computing. Working together, these forces enable the
creation of a unified and highly connected infrat Previous page

structure in which remote access becomes feasible.

As a result, engineers can monitor real-time performance data across multiple plants and collaborate with
on-site personnel to address maintenance and repair
issues.
For example, a global packaged foods producer
could correlate its data captured remotely from plants
around the world to gain deeper insights into how to
best keep its lines and processes running, Conti explains. The company could also remotely monitor realtime health information for equipment and systems
at its manufacturing sites. If any faults, warnings or
abnormalities are detected, notifications can automatically be sent to the appropriate subject matter expert to
diagnose the potential issue.
Should a downtime event materialize, however, the
companys remotely based engineers can immediately
review any key parameters to more quickly diagnose
the root cause and work with on-site employees to take
corrective action.
Connecting the plant to the appropriate subject
matter experts also creates the ability for remote

Deploying remote access and all

its advantages also likely
will require a new level
of collaboration between
IT and OT staff.
management of critical manufacturing infrastructure.
Functions such as asset management, disaster recovery,
patch management and install-base evaluations are all
possible through secure remote access, Conti says.
Connecting the right information to the right people
and giving them the tools to be able to make wellinformed decisions are key benefits.
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Remote monitoring also can help manufacturers recalibrate their talent in preparation for workforce issues
on the horizon. Not only are many of todays skilled
workers heading toward retirement, but The Connected
Enterprise is creating demand for a new breed of workers with both OT and IT expertise.
The shortage of skilled workers continues to be

a driving force in the trend toward doing more with

fewer staff, says Spectrum Controls Lindsey. This
trend has helped highlight remote access not only as a
way to reduce travel costs, but as a method to reduce
productivity lost to employee travel time.
Security concerns can cause some end-users to
hesitate to consider connecting their equipment with

>> Are You Ready for the Convergence of IT and OT?

Five-day course from Rockwell Automation and Cisco helps IT and operations technology professionals
to manage and administer industrial network systems.
By Anglique Fehr, commercial programs manager, Global Solutions & Services, Rockwell Automation
The industrial plant floor is transforming. For decades,
information technology (IT) and operations technology (OT) have operated in parallel. However, with the
convergence of network technologies, the line between
the two is blurring.
As often happens during times of great change, the
need for specific skill sets is outpacing the availability
of people with those skills. The demand for people who
understand the exchange between IT and OT is big
and the need continues to increase as the industrial
plant floor and the corporate enterprise become more
connected.
In fact, to help scale the Internet of Things (IoT), its
estimated that 220,000 IT/OT engineers are needed
every year.
To help ensure IT and OT professionals are equipped
with the broad skill sets they need to manage and administer industrial network systems, Rockwell Automation
and its Strategic Alliance Partner Cisco jointly developed
the Industrial Networking Specialist certification (exam ID
600-601), supported by a hands-on, lab-based course:
Managing Industrial Networks with Cisco Networking
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Technologies (IMINS).
The course is designed for:
Control engineers working with Ethernet networks.
IT engineers who want to diversify their skills
intoindustrial environments.
Systems integrators in the manufacturing, process
control, and oil and gas industries who install,
maintain and troubleshoot industrial network
systems.
This five-day, instructor led course, including a
lab, provides plant administrators, control system
engineers and network engineers with the critical
knowledge needed to support and maintain the networking technologies needed in todays connected
plants and enterprises.
Unlike other industrial networking programs, the
IMINS program tests hands-on skills through simulations
as well as theoretical knowledge, ensuring attendees are
prepared for real-world implementations.
Classes are scheduled in the United States, Canada
and Europe. Find a course in your area, and prepare
yourself for the convergence of IT and OT.
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Virtualization provides features

such as high availability and
fault tolerance to help improve
uptime of the process system,
and therefore controlled
application.

remote access to their OEM. Industrial routers have

been used to make secure connections in many industries for many years, Pearson Packagings Pritima
observes. The technology is proven.
David Myren, controls engineer with Rockwell
Automation OEM Partner Aagard Inc., agrees. We let
our customers know we support them the best we can
regardless of remote communication or not, but remote
communication implemented properly is very secure.
And providing remote communication will significantly reduce troubleshooting time and can eliminate
service trips to their facility that may otherwise be
necessary, he says.
For security concerns, weve found it beneficial
to consider the business case for remote access, adds
Lindsey. If you have a good understanding of the benefits your business will gain by implementing remote
access, you can better determine how much risk is
reasonable to accept. Email is a great example of a technology that is generally accepted as providing enough
benefit to outweigh the risk it poses.
An example of an OEM who uses secure remote access

to help its customers is LORAM Maintenance of the Way

Inc., in Hamel, Minnesota. The company supplies railway
track maintenance machinery, and it cut downtime and
costs for itself and its customers after implementing a
Rockwell Automation manufacturing-intelligence system
with remote-monitoring capabilities on its newest line of
rail grinders that collects performance data for real-time
troubleshooting, maintenance and electronic reporting.
Before the new system, access to machine data,
troubleshooting and diagnostics on up to 80 machines
in the field were time-consuming and difficult, relying
on the technical support staff to walk the on-site team
through the issue and potential fixes. All data was in
PLC code, requiring it to be retrieved and analyzed by
a technician who could properly interpret the data. In
addition, the data-log format wasnt easily readable,
customizable or searchable.
Now, secure remote access to real-time machine
data provides LORAM rail grinder technicians the
ability to see issues as they happen and to proactively
plan for similar issues that could occur in the future.
Using remote diagnostics for predictive-maintenance
activities has reduced mean time to failure (MTTF)
while increasing mean time to repair (MTTR). Also,
electronic reporting makes accessing, searching and
analyzing data much easier on the new system.
Learn more by watching this video case study
about LORAM.

>> Free White Paper

Click here to download the free white paper,
Virtualization for Process Automation Systems,
designed to help users in the food and beverage, household and personal care, life sciences
and other process industries to understand IT
hardware and software requirements. The paper
also provides IT personnel with an overview
of virtualization for process automation applications, and information about how to select
hardware and build a virtual PlantPAx process
control system from Rockwell Automation.

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>> As Industrial Networks Converge, Skill Sets Must Broaden

By John Nesi, vice president, Market Development, Rockwell Automation
In the industrial sector,
were acutely familiar
with the challenges of
workforce readiness.
Weve been working for
years to find, attract and
inspire the workers who
will fill the place of many
soon-to-be-retiring professionals. However, retireJohn Nesi, Rockwell Automation ment isnt the only issue
affecting worker readiness. Major changes to how industrial firms operate
are proving to have major effects on their workforces.
Specifically, the convergence of information technology (IT) and operations technology (OT) presents significant challenges to the professionals responsible for
installing, maintaining, upgrading and troubleshooting
those technologies.
IT and OT professionals historically have worked in
silos, with IT delegated to the business side and OT
to the industrial zone. The Internet of Things (IoT) is
changing that. Todays industrial organizations can
connect, communicate and collaborate across the
entire enterprise, from executive suites to plant floors,
supply chain partners and remote locations.
As a result, the lines that traditionally divided IT and
OT are blurring. These workers increasingly require
skills beyond their core areas of expertise to be able
to support IT, networking and control-system functions.

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Cisco recently introduced the Cisco Industrial

Networking Specialist certification to ensure IT
and OT professionals are equipped with the skill
sets they need to manage and administer industrial
network systems. The certification exam tests both
hands-on skills and knowledge of critical topics,
such as the Open System Interconnection (OSI)
model, network and industrial devices, safety protocols, and environmental and industrial standards.
Rockwell Automation and Cisco also have
launched a hands-on, lab-based course to prepare
IT and OT professionals for the exam and give
them the foundational skills theyll need for the
connected enterprises of tomorrow. The first-of-itskind course, Managing Industrial Networks with
Cisco Networking Technologies (IMINS), helps IT
and control-system engineers install, maintain and
troubleshoot industrial network systems.
The IoT presents opportunities that are only limited to our imagination. Leading organizations already are taking advantage of smart devices and
converged-network technologies, and most others
will soon enough discover they need to embrace
them if they want to remain competitive.
New technologies are accelerating access to
insightful possibilities, but we should never forget
that our greatest assets will always be our employees, and we must educate and empower those
who can best make this great leap forward a
successful one.

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New Approach for IT and OT

>> Technology Trends of 2015 for Food

Deploying remote access and all its advantages is

requiring a new level of collaboration between IT and
OT staff, which, as mentioned previously, is happening
more and more with manufacturing convergence and
The Connected Enterprise. IT personnel already might
be familiar with remote-access tools, but theyll need to
share that knowledge with OT personnel as theyre introduced to the technology, according to Paul Brooks,
business development manager, Rockwell Automation.
Similarly, IT expertise typically doesnt extend to
production equipment, meaning OT personnel will
need to confirm the remote-monitoring system meets
the unique demands of the plant floor.
For example, resolving an IT issue within a few
hours is generally acceptable in an office environment.
In a food processing operation, thats lost profit. As
a result, a remote-monitoring system that supports
predictive or preventive maintenance and immediate
corrective action is mandatory.
Accessing and collecting more data via secure remote
access also raises the question of where and how to
store it, Brooks notes. Rather than spending limited
capital resources on physical servers and hoping your
investment reaches 100% capacity down the road, the
cloud offers greater flexibility and can scale to changing
needs. It also enables new programming models, new
IT infrastructure and new business models.

& Beverage, Household & Personal

Care, and Life Sciences Companies

1
2
3
4
5
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Computer Virtualization Grows

As the trend of increased use of secure remote access by

other OEMs and end user continues, virtualization also
is moving to the forefront of the end-users efforts to
increase efficiency in every area possible.
Virtualization has benefits that apply to both traditional enterprise IT and industrial automation, such as
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Increased implementation of
The Connected Enterprise.

Expanding use of secure remote asset

management from end users to OEMs
to help prevent machine downtime and
to enhance track-and-trace capabilities.

Greater demand for OEMs to provide

serialization-ready machines.

Increasing use of plant-floor virtualization

to support and enhance remote asset
management as the Internet of Things
(IoT), the cloud, big data, wireless
technology and more continue to grow.
Further convergence of information
technology (IT) and operations
technology (OT) operations as part
of The Connected Enterprise.

Continuing focus on machine safety.

More migration to the modern distributed control system (DCS) that integrates
process control, discrete control, power
control and safety control.

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server hardware consolidation, lower energy consumption, and reduced physical server footprint. One of the
most important benefits for process automation systems is hardware independence: the ability to extend
the life cycle of a control system.
Virtualization provides features such as high availability and fault tolerance to help improve uptime of
the process system, and therefore controlled application. The ability to take a snapshot of the current
software configuration, implement changes, and revert
to previous configurations if needed, decreases risk
and improves start-up time. This helps decrease the
risk of software upgrades, configuration changes
and OS patching.

production, explains Joe Whyte, corporate accounts

manager & global serialization lead, Rockwell Automation.
In such mission-critical scenarios, the ability to
provide global application support with remote monitoring and diagnostics that can quickly identify the
source of a problem and get the plant back in production becomes paramount, Whyte says.
Greater supply chain integrity offers more than just
compliance. For manufacturers, it also can deliver
reverse-logistics benefits, more accurate and efficient
recalls, real-time consumption data that improves
forecasting and aligns production with demand, and

Serialization for Efficient Traceability

Secure remote monitoring does more than help prevent

downtime and save costs via preventive and predictive
maintenance. Track-and-trace activities can benefit
greatly from remote monitoring, and the demand for
OEMs to provide serialization-ready machines is growing. It has become more important than ever with the
rise of internet pharmacies, under-regulated wholesalers and re-packagers, and advances in counterfeiting
technology (see article on page 22).
Nations around the world are implementing
serialization-based, anti-counterfeiting regulations, including the United States, the European Union, Brazil,
China and many more. Serialization will allow regulators to track the movement of products from a manufacturers production site, through their entire supply
chain, to the point of dispense or point of purchase.
The most important thing to remember for both
OEMs and manufacturers is that if any part of a
serialization system fails in a regulated industry, entire
production lines must come to a halt, and depending
on the level of failure, an entire plant may have to stop
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>> VIDEO: Smart Solutions for the Food

and Beverage Industry

Food and beverage producers around the world are

challenged by a dynamic environment driven by consumers who demand better quality, more choices and
low costs. In this short video, learn how through industry
experience, innovative automation and safety offerings,
Rockwell Automation provides end users, integrators
and OEMs with the tools, data and guidance required
to differentiate themselves from the competition.
Watch the video now!
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more customer-specific marketing programs. As a result,

consumer goods manufacturers can realize significant
business benefits from deploying serialization and supplychain traceability programs.
OEMs are taking two steps to meet the growing
demand from their customers for serialization-ready machines, Whyte explains. First, new packaging machinery
is being delivered with serialization printing, inspection
and product reintroduction and repackaging capabilities.

Secondly, OEMs are manufacturing product

handling, print and barcode verification stations that
can be inserted between the packaging machines on
existing production lines with minimal interruption
to production and minimal validation burden during
installation, Whyte notes.
He says by using commercial off-the-shelf Logix
programmable automation controllers (PACs) with
EtherNet/IP-enabled printer and inspection systems,
OEMs are delivering serialization-ready machines that
connect seamlessly to a manufacturers higher-level
serialization data management infrastructure.
The use of Stratix managed Ethernet switches also
helps verify the machines control functions and the
users serialization data-management system functions
remain segmented and separated, adds Whyte. This
segmented network architecture approach maintains
the integrity of the production-critical serialization
data-management process.

Modern DCS

>> Rockwell Automation Develops

Serialization and remote asset management provide great

advantages in supporting increasingly tighter compliance
requirements as manufacturers are simultaneously competing for market share. Manufacturers also must meet
demand for new sources of productivity and margin
growth while using the same automation approach and
control system strategy theyve been using for decades.
To address these challenges, more end users are migrating to a modern distributed control system (DCS).
Typically, automation uses a mixture of diverse
systems specifically developed for the tasks they
control, based on the technology thats available.
Manufacturing uses one system for process control,
another for discrete control, and another for power
control.

Resources with Strategic Partners

In support of The Connected Enterprise and network convergence, Rockwell Automation and Cisco
have developed the Converged Plant-wide Ethernet
Reference Architecture to provide tested, validated
network design guidance to help manufacturers
achieve the benefits of converging industrial automation and business systems.
In addition, Rockwell Automation and its Strategic
Alliance Partners Cisco and Panduit created
www.industrialIP.org, an educational community
resource where OEMs and users can exchange information to help deploy IP-based infrastructures.

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>> Study: Personal Care Packaging Market Headed for Growth

A new market assessment report,
Personal Care Market Assessment,
predicts 5.5% annual growth for
the global personal care packaging
market through 2019. The survey
from PMMI, The Association for
Packaging and Processing Technologies, also examines global trends,
drivers and opportunities from the
choice of materials to operations.
Bottles account for 30% of the
market and are expected to grow
an additional 28% through 2019,
making them the most commonly
used container format in this market.
As for materials, plastic is the most
popular, accounting for 61% of
materials used. The study projects
plastic will remain dominant,
growing 12% by 2019.

Areas of Growth for Personal Care Packaging

Plenty of Room for Growth
UNITED STATES
The personal care
packaging market
is estimated at $4
to $5.1 billion.

GLOBALLY
The personal care packaging
market is expected to increase
with an estimated annual
growth rate of 5.5% over the
next five years, reaching up
to $38.1 billion by 2019.

Boxes, Bottles & Tubes

Bottles are the most common
packaging type used and
are expected to grow 28%
by 2019.
Cartons have seen the
most growth since 2010,
increasing from 9% of the
market to 19%.

About two-thirds of personal

care products come in liquid form,
while about 20% come as
semi-solids, solids and powder.

Source: PMMI, The Association for Packaging and Processing Technologies

For example, specific functions in a plant with highspeed, discrete logic might be controlled using dedicated programmable logic controllers (PLCs), while
traditional DCSs are used when multiple controllers
and multiple points of access need to be connected and
accessible throughout the plant. The main process area
in a facility typically is automated using a dedicated
DCS. Maintaining multiple disparate automation systems can strain operations and support resources while
restricting flexibility.
A modern DCS, instead, delivers all of the core
capabilities of a DCS for process control, but its built
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Plastic is the most popular

packaging material by far
and is expected to grow
12% by 2019.

on contemporary technology that easily integrates

with other automation systems, operators activities,
and critical business systems. A modern DCS is built
using plant-wide control technologies. Process control,
discrete control, power control and safety control no
longer have to be a choice of separate technologies.
Manufacturers can choose to implement a plant-wide
control system.
In the past, a DCS was designed only to directly
control critical equipment and was otherwise limited to
basic supervisory roles. This was driven by their cost and
complexity. As the process assets are considered criti12

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cal, the DCS architectures were hardened to accept vast

amounts of I/O and perform in a very reliable manner.
A modern DCS must also perform in a similar fashion, but now the architecture has been expanded to be
inclusive of plant-wide systems. Additionally, since plant
configurations rarely remain static over time, its necessary for the platform to be scalable as it incorporates
additions per production and budget availability.
The use of common automation technologies enables
seamless integration of the modern DCS with plantfloor and business systems, creating more opportunity
for plant-wide optimization and benefits of The Connected Enterprise.
To learn much more about a modern DCS, download this free white paper.

Studies show that about 90% of machinery safety

incidents occur outside of normal operation.
Rockwell Automation, working with cultural
development firms, insurance providers and other
partners, has developed the Safety Maturity Index.
It provides end users insight into their safety programs and the steps they can take to optimize them.
It can help measure and evaluate a safety program
against the three key pillars culture, compliance
and capital on a scale of one to four.
Plant operators can complete a self-guided, online
assessment consisting of a series of questions for
each safety category. Then, users can see where they
score in the Safety Maturity Index levels in safety
culture, compliance and capital. More importantly,
it provides an opportunity to develop a roadmap to
best-in-class performance.
Watch this video to learn more about the Safety
Maturity Index.

Machine Safety Measurement Tool

Serialization helps address product integrity and

safety, but you also need to make sure youre addressing machine safety. The workforce is aging in every
region of the world, which makes safety a critical
issue. Temporary and younger workers (under age
25) are at much higher risk of workplace injury, and
older workers can develop physical limitations that
can increase their susceptibility to repetitive strain
injuries and reduce their effectiveness or availability.
These issues impact machinery design and procurement substantially, increasing the need to mitigate risks
while improving safety systems and ease of use.
Safety is a fundamental element of risk management,
sustainability and corporate social responsibility critical to the long-term value of any business. Performing
a proper task-based risk assessment and considering all
human elements that will be involved with the machine
is critical, says Chris Brogli, FS TV Expert, global
safety market development at Rockwell Automation.
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Connecting is Power

Manufacturers can use sophisticated technology

to keep pace with the need to reduce costs while
increasing flexibility and productivity in a market
thats losing its skilled workers, and OEMs are stepping forward to design equipment to help end users
do that. With technologies that optimize secure
remote asset management, serialization, plant floor
virtualization and machine safety, The Connected
Enterprise is part of best practices for high-performing process manufacturers.
Learn about all the Rockwell Automation OEM Partners
who can help you.
Learn about Rockwell Automation OEM solutions.
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 The complex bread-baking process at Kings Hawaiian requires 11 machines,

each manufactured by a different original equipment manufacturer.

How Kings Hawaiian Created a

Common Network Infrastructure
Learn how the popular bread-baking company standardized technology requirements for multiple
OEMs and eased integration and data sharing in a new facility.

>>

The distinctive sweetness of Kings Hawaiian

bread has made it an American favorite and
fueled the growth of the company. Robert Taira created
the recipe for the iconic round loaves 50 years ago in
Hawaii. Tairas business Kings Bakery in Honolulu
became a destination for tourists who often shipped
bread back to the mainland as gifts for friends and family.
As the appetite for the Kings bread grew, Taira
moved his family to Southern California and built a
30,000-sq.-ft. facility. The breads popularity continued
to expand, and so did the familys operation. By 2010,
its California factory and bakery were operating 24/7,
and consumer demand was spreading across the country.
The company had also expanded its product line beyond
the signature round loaves to baking dinner rolls, sub
rolls and sandwich buns.
Kings Hawaiians leaders decided to build a new
facility in the Eastern United States so the company
could get its products to store shelves more quickly and
cost-effectively.

machines, each manufactured by a different original

equipment manufacturer (OEM), with a control and
information platform requiring a unique design environment, user interface and vendor support model.
While the initial project deadline was tight, Kings
Hawaiian also wanted to address its long-term needs for
the plants information infrastructure.
Weve been a small, family-run company, so building a new plant 3,500 miles away in Georgia was a huge
step, says Mike Williams, director of engineering for
Kings Hawaiian. We wanted to be sure we could look
in on the process remotely from California to make sure
production meets our customers expectations.
Kings Hawaiian also wanted advanced data-collection capabilities to help it consistently bake the highestquality products, as well as gain operational efficiencies
across the enterprise.
As a company, we havent done a lot of formal reporting or evaluation, and whatever data weve captured
has basically been penciled in, Williams explains.
Since we were building a new facility, we wanted the
infrastructure needed to capture information from
all fronts.
With more than 11 machines required for our production process, we couldnt just turn each OEM loose
without clear specifications and an overall integrated

Assessing Plant Needs

Kings Hawaiian chose to build a highly automated

125,000-sq.-ft. facility in Oakwood, Georgia, and set
a goal to be up and running within just 10 months.
The entire bread-baking process required 11 specialized
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design architecture, Williams says. If we had, we

front so they could provide a return that was closer to
would have had to learn several types of PLCs [program- what we actually wanted versus what we started with.
mable logic controllers] and HMIs [human-machine
As the integrator on the project, BCI gathered the
interfaces], and stock several varieties of the same part
controller and HMI requirements from each OEM
for repairs.

The new facility opened one week

earlier than planned and doubled
the companys bread production.

Innovative Control Platform

In less than a year, the company had to specify and

procure equipment from more than seven suppliers,
integrate it, and test its reliability to meet production
volumes of 8,000 lbs. of bread per hour.
Williams worked with his team and Bachelor Controls
Inc. (BCI), a Rockwell Automation Solution Partner, to
create an architecture that would enable Kings Hawaiian to meet its short-term goals of getting the equipment
up and running to open the plant on time, while laying
the groundwork for information gathering and sharing
throughout the enterprise.
BCI put a lot of emphasis on front-end design and
forced me to be a better customer, says Williams. They
made us work hard to answer important questions up

and wrote an overall specification standardized on the

Rockwell Automation Integrated Architecture system.
BCI then worked with Rockwell Automation to validate
the systems design.
We wanted to establish a common configuration for
the OEMs so that everything would connect easily and
communicate well, says Rusty Bailey, Memphis office
branch manager, BCI. We also understood the bigger
picture: Kings Hawaiian needed to be able to monitor
its process across the enterprise and make intelligent
decisions to increase production efficiency.
BCI directed all the OEMs to use the Allen-Bradley
ControlLogix programmable automation
controller (PAC). It features an integrated
platform for scalable motion and machine
control in a single programming environment that provides Kings Hawaiian with
fewer spare parts to maintain, while the control platforms openness helps ensure easy
integration with third-party components.
The specifications also required a standardized approach to the visualization and
information software used on each machine.
FactoryTalk View Site Edition software is
used on each machine to simplify application development and training a crucial
time-saving element on a fast-turnaround
project.
BCI specified the Site Edition version of
the software to make it easier for the Kings Hawaiian
team to manage upgrades on its own long-term. Each

FactoryTalk ViewPoint allows Kings Hawaiian to monitor operations

remotely from anywhere Internet access is available.

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The common network architecture

enabled us to get this plant up
and operational in a matter of
weeks instead of months.
Mike Williams, Kings Hawaiian.

produces real-time dashboards and web-based reports

with unique situational and historical context for
different users. Williams and others across the company can access the data using FactoryTalk ViewPoint
software, which allows them to monitor operations
remotely from any location where Internet access
is available.

version of the visualization software is then running on

Allen-Bradley industrial environment computers with
a separate touch screen and solid-state hard drive to
protect the system and reduce the number of failures in
the future.
For the packaging machines, BCI specified AllenBradley CompactLogix PACs and Allen-Bradley
PanelView Plus HMIs. The scalability of the Integrated Architecture system allowed BCI to use the smaller
controller, which provides all the benefits of the Logix
control platform, but in a smaller form factor.
The entire plant communicates via EtherNet/IP.
The single network architecture helped the company
get the plant online faster and lowered the Total Cost
to Design, Development and DeliverSM the machines.
EtherNet/IP also allows Kings Hawaiian engineers to
remotely access, diagnose and service their machines
from two redundant VMware servers located in a central control room.
By standardizing on the Integrated Architecture
system, our people are now able to go from one process
to another within the plant, and use the same software
and same knowledge to address any number of issues,
Williams explains. The architecture also allows us to
collect vast amounts of data about everything from
oven temperatures and bake times to scale weights and
maintenance operations that previously we couldnt
manage manually.
Production information is saved, stored and managed using FactoryTalk Historian software that collects
and archives time-series data from all equipment and
data sources in the plant. FactoryTalk VantagePoint
software correlates and aggregates the information and
t Previous page

Product Expansion

The new facility opened in October 2011 one week

earlier than planned. Immediately, it doubled the companys bread production.
The facility is producing the companys two largestselling products the signature round bread and the
12-pack dinner rolls. Because the plant was built for
future growth, it has the capacity to add another line.
Long-term, the company plans to produce all product
types at the Georgia location.
The common network architecture enabled us to
get this plant up and operational in a matter of weeks
instead of months, says Williams. And through the
continuity of materials, were able to stock spare parts
were familiar with, reducing lost production time
during a failure. This plant gives Kings Hawaiian the
capacity we need for the foreseeable future.
Stage two of the project developing the centralized data collection and control system was completed in the months after the plant went live.
A special team will help determine what data is most
valuable for the plants various departments, Williams
explains. Each business owner from maintenance
to accounting to sanitation will have a key interest,
so its going to take a while to find out what data they
need. Then well determine the actual usefulness of
that information. This is a learning process, though we
all know the end goal to put information to work
for the greatest value.
Learn more about Rockwell Automation Food Industry
Solutions.
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FACILITATING FSMA COMPLIANCE WITH

TECHNOLOGY
The FDA set the food safety compliance objective, and leaves it up to you to figure out how to
get there. Here is some guidance on what you need.
By Jim Toman, Lead Consultant - Food and Beverage Services
and Ian Tooke, Director - Consulting Services, Grantek Systems Integration

>>

The Food Safety Modernization Act (FSMA)

will revolutionize food safety in the United
States, and will have a ripple effect across the globe. For
the past 50 years, the food industry has been transitioning
from a system of reacting to food safety issues toward one
in which systems are designed to guard against contamination and prevent issues from occurring in the first place.
When it comes to the FSMA, where do you start? Of
the seven rules proposed by the U.S. Food & Drug Administration (FDA) thus far, the majority are hundreds of
pages in length, and understanding whats required can be
confusing. With additional rules still expected to come, it
can be difficult to plan for the future. And yet, there is no
time to delay, because the rules are coming fast. So far, the
FDA has released the proposed rules shown in the illustration on page 21, with court-defined dates for finalization.
The proposed rules might seem complicated, but regulatory compliance is well within reach. While regulatory
compliance is a baseline requirement, the ability to concurrently satisfy other business needs helps ease the burden of
implementing a change.

past several decades, and is required for certain types of

food products in the United States (seafood, juice, meat
and poultry). FMSA will require the breadth of the food
industry to build upon HACCP and formalize a comprehensive system to address food safety. Standards will be
instituted for fresh produce, food processing, transportation and imports.
Rather than issuing prescriptive, product-specific requirements, the FDA sets the objective and leaves it up to
companies to figure out how to get there. While the FDA
doesnt require the use of any specific system, technology,
or the use of any degree of automation, its clear that the
FDA wants companies to embrace technology. Therefore,
complying with many aspects of the proposed rules will be
much easier if firms leverage technology.
Regardless of the approach taken, several overarching
ingredients are needed for FSMA compliance that also
are critical for your brand protection:
Rapid Response. Whether its recognizing that a
process is out of control or providing records to the FDA,
companies need to be able to respond quickly.
Consistency. When considerable effort goes into
developing a plan to achieve food safety, the consistent
implementation of those policies is critical.
Documentation. The foundational role that docu-

Food Safety Evolution

The Hazard Analysis Critical Control Point (HACCP)

approach to food safety has been gaining ground over the
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Preventive controls prevent,

eliminate or reduce the known
hazard to an acceptable level for
safe consumption of food.

been considered current Good Manufacturing Practices

(cGMPs) may be updated and modernized, thus falling
under Preventive Controls. We look at this later.
Within the realm of Preventive Controls, process controls are the most familiar. These are the controls that are
mentation will play in demonstrating that food safety is
typically associated with HACCP and are recognized as
under control even when a regulator or auditor isnt
the critical control points for food safety. With Preventive
looking cant be overstated.
Controls, the FDA expects that food manufacturers will
Analysis. The food industry collects a lot of data.
continue to heavily rely upon process controls. Consistent
However, bringing the data together to make sense of
with what is seen in existing HACCP regulations, the
the bigger picture often is lacking. Trending data gives
FDA would require that the following approach be followed:
companies a heads up to anticipate looming issues and also
Validation. Whatever process control is selected must
can reveal opportunities to optimize systems and increase
efficiency. Fortunately, most food companies take food
safety seriously and continue to look for opportunities to
improve what they are doing. While FSMA revolutionizes
the FDAs food safety authorities, an individual companys
path to compliance should be more of an evolution, not a
revolution.

Preventive Controls

Preventive controls prevent, eliminate or reduce the known

hazard to an acceptable level for safe consumption of food.
Under FSMA, the FDA will have a legislative mandate to
require comprehensive, science-based preventive controls
across the food supply. For food facilities, the mandatory
preventive controls involves:
Evaluating the hazards that could affect food safety.
Specifying what preventive steps, or controls, will
be put in place to significantly minimize or prevent the
hazards.
Specifying how the facility will monitor these controls
to ensure they are working.
Maintaining routine records of the monitoring.
Specifying what actions the facility will take to correct
problems that arise. (Final rule due 18 months following
enactment).
Moving forward, some activities that have historically
t Previous page

>> VIDEO:

Tyson Foods - Hillshire Brands Boosts

Compliance by Using Manufacturing
Intelligence Software

In this video, see how a Tyson Foods - Hillshire

Brands corn dog facility uses Rockwell Automation
FactoryTalk manufacturing intelligence software to
increase plant visibility for new U.S. Food and Drug
Administration food-safety regulations to help improve
compliance and reduce quality deviations and waste.
Watch the video now!
19

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work. If a process is being employed, for example, to

control for Salmonella, the food producer must be able to
show that the process will destroy the pathogen effectively.
In this example, this means knowing the expected and
worst case levels of the pathogen so that the amount of
kill can be determined.
Then, the parameters that will accomplish this reduction need to be tested. This should be done using the food
products to which the process will be applied, under the most
real-to-life conditions possible, including using the actual
equipment that will be used during production. In some
cases, scientific studies might already have been published
and can be used as a starting point for the validation studies.
Establishment of Parameters. The validation studies
will help a company establish the conditions needed for an
effective process. These could include factors such as time,
temperature, line speed, humidity, antimicrobial concentration, etc.
Any change, such as a change in formulation or processing equipment, should prompt a re-evaluation of the parameters to ensure that the process is still valid. Automated

ticipated, and facilities need to show they have thought

through what could go wrong and have a plan to address
issues if they occur.
When issues do occur, the facility needs to keep records
of the event and show they followed the course of action
specified in their food safety plan. In some cases, these
types of issues prompt firms to reconsider their approaches
and start looking for cost-effective solutions to prevent
recurrence.
Verification. The FDA has proposed a few ways facilities will need to show that their entire food safety system
is working as anticipated. Recordkeeping and documentation, and a review of those records as well as a re-evaluation of the overall food safety plan would be required.

Examples of Preventive Controls

Allergen Control. In response to the increasing fraction of

the population with food allergies, the FDA and the food
industry have cast a spotlight on allergen controls. For
facilities that have identified food allergens as hazards that
are reasonably likely to occur, implementating allergen
controls would be required.
This can encompass several different activities, including appropriate sanitation between different allergens
as well as runs without allergens, appropriate storage of
allergens, material verification, and label control and
verification.
Did you know that 44% of all the entries to the
FDA Reportable Food Registry were due to undeclared
allergens?
Supplier Verification. In some cases, a facility might
not have a way to control a hazard; it might rely on a supplier for control. In this instance, the FDA is expected to
propose that supplier controls be enacted in such a way
that the receiving facility is assured that their supplier is
adequately controlling hazards.
While the FDAs exact requirements werent published
at the time of this writing, the FDA has verbally confirmed

System failures need to be

anticipated, and facilities need
to show they have thought
through what could go wrong
and have a plan.
recipe management for equipment and process parameters
can help food producers meet this need.
Monitoring. Once the parameters are set, its critical
that they be monitored. A Historian database can be used
to capture these process parameters such as temperature,
pressure, time, etc. Best-in-class systems are complete
with trending of data and statistical process control (SPC)
alarms to give an advance warning if the system is trending out of bounds.
Corrective Actions. System failures need to be ant Previous page

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FDA Proposed FSMA Rules and Defined Dates for Finalization

FDAs FSMA Regulation

Final Rule Deadline

Preventive Controls-Human Food

Aug 30, 2015

Preventive Controls-Animal Food

Aug 30, 2015

Produce Safety

October 31, 2015

3rd-Party Accreditation of Auditors

October 31, 2015

Sanitary Transport

March 31, 2016

Intentional Adulteration/Food Defense

May 30, 2016

Large businesses have 12 months to comply once the FSMA rules are finalized; small businesses have 24 months to comply; and very small
businesses have 36 months, according to the FDA.

that such a requirement will be proposed.

The issuance of Certificates of Analysis (CoAs) by suppliers is fairly common within the food industry. However,
they have little value if a receiving company doesnt know
how to review and verify them properly. A pile of papers in
a file cabinet or emails in a folder are inadequate to demonstrate that youre using CoAs to control your supplier.
The preferred approach is to automate the review of
COAs. Implementing an automated traceability and genealogy system covering raw materials receipt and linking
laboratory analysis of raw materials samples to the specific
received lots can create a traceable and searchable record
that proves control. It also can be used to manage acceptance of raw materials from suppliers.
Forensic Traceability. In the event of a food safety
incident, the FDA is aiming for a fast response. An automated track-and-trace system, with genealogy records
including key data elements (KDEs) captured at critical
tracking events (CTEs) and further detail of equipment
and production routings, can facilitate fast forensic investigation and build trust with the FDA and consumers.

ner. For some companies, this change will be prompted

by FSMA; for others, the change will result from the
desire to up their game and remain best-in-class. Regardless of the driver, leading companies are continually
on the lookout for ways to enhance their operations while
maintaining profitability.
Grantek Systems Integration Inc., based in Burlington, Ontario, Canada, is a Rockwell Automation
Enterprise Solution Partner, an elite group of professional
IT service organizations that have demonstrated design,
delivery and support competency around the enterprise
class of Rockwell Automation FactoryTalk manufacturing
information solutions.
The firm is a system integrator and solution provider that
specializes in manufacturing IT solutions, manufacturing
automation, industrial safety and manufacturing consulting.
Grantek assists clients with processes and solutions including
packaging, control systems design, MES implementation,
electrical design and more. With more 180 employees, the
firm has offices in British Columbia, California, Illinois,
Pennsylvania, Ohio, Ontario and Quebec.

Compliance Isnt Optional

Grantek Systems Integration Inc.

www.rockwellautomation.com/go/p-grantek

The FSMA is coming, and change is just around the cort Previous page

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The Rise of Serialization Regulation:

What to Know and Do
A comprehensive and holistic pharmaceutical serialization system can offer significant benefits
beyond regulatory compliance.
By Joe Whyte, Global Serialization Lead, Rockwell Automation

>>

The rise of Internet pharmacies. Under-regulated wholesalers and repackagers. Advances

in counterfeiting technology. These are only a few of the
opportunities that drug counterfeiters have seized upon
to turn a profit at the expense of consumers health and
manufacturers reputations.
As a result, a number of countries around the world
are rolling out serialization-based anti-counterfeiting
regulations. These include the European Unions
Falsified Medicines Directive, the United States Drug
Supply Chain Security Act and Chinas electronic drug
supervision code requirement.
Heres what you need to know.

scan, and permits the complete product event history to

be reviewed or audited should an issue arise.
While serialization regulations vary by country or
region, some general requirements pharmaceutical
manufacturers are expected to comply with include:
The ability to generate, acquire and manage a UID
for each saleable item.
Linking package-level serial numbers in parent/
child data relationships, such as pallets to cases, cases to
cartons or cartons to saleable items.
Storage of UID information in a secure database
that can be shared with trading partners.
Validation that serialization data matches the
physical product received.
Confirmation that products have complete and
accurate documentation.

The Basics

Serialization uses a numeric or alphanumeric code

known as a unique identification (UID) to realize full
track-and-trace capabilities of a product throughout the
supply chain, from its manufacturing origin through
distribution channels and down to the point of sale.
Production, transportation and point-of-sale event
information is recorded and stored in a central database. This allows a product to be authenticated as legitimate through something as simple as a quick barcode
t Previous page

Impact on Production

While governmental regulations lay out detailed requirements for what serialization systems must accomplish,
they dont specify how pharmaceutical manufacturers
should implement their serialization systems. This gives
manufacturers some flexibility in their approach, but still
leaves them facing a number of challenges.
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Its best if unique identification

(UID) numbers are random number
sets versus consecutive numbers
to help eliminate the likelihood of
predictable UIDs.

On the operations side,

pharmaceutical manufacturers
must try to fully incorporate
the serialization system into
an existing control architecture than can include legacy
equipment and multiple different device vendors, networks, protocols and proprietary platforms.
A serialization solution
While governmental
must also be compatible with
all package types and countryregulations lay out detailed
specific UID formatting
requirements for what
requirements to ensure compliserialization systems must
ance and uninterrupted product
accomplish, they dont
changeovers. It should also
specify how pharmaceutical manufacturers should
support seamless integration
implement their serialization of serialization components,
such as high-speed printers and
systems. Joe Whyte,
vision-inspection cameras.
Rockwell Automation
A variety of software-related
challenges also exist regarding the generation, integration and management of serialization data. Industry
generally follows the ANSI/ISA-95 standard, which
provides a four-level model for interfacing from the
plant floor to the enterprise. Serialization-relevant data
must be distributed widely over control and information systems across all four of these levels.
Generated UID numbers must be unique to the
product, and its best if theyre random number sets
versus consecutive numbers to help eliminate the likelit Previous page

hood of predictable UIDs. The system must be able

to handle a large volume of data management to meet
UID printing and verification demands in high-speed
environments.
Data must also be secure yet seamlessly integrated
across multiple levels, from packaging and palletizing
machines on the plant floor to manufacturing execution
systems (MES) and enterprise resource planning (ERP)
systems to a cloud-based event repository.

Solutions

Some manufacturers might opt to develop their own

customized serialization system to harmonize the
system with their existing equipment and processes.
However, this black box approach can lead to support
issues, parts shortages and knowledge-transfer problems
in the long term. The time and effort needed to design,
test and commission a custom system also can be costly
and disruptive to operations.
Pharmaceutical manufacturers should instead
consider basing their system on a modular and scalable
off-the-shelf control and information platform that can
be integrated easily into their existing lines. Specifically,
by tapping a software platform that also offers MES
and electronic batch recording (EBR) capabilities, a
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serialization system can help address global serialization

requirements, including necessary data capabilities and
high-speed device management of serialization components all while minimizing production interruptions
or validation burdens.
Additionally, a serialization system that uses an Electronic Product Code Information Services (EPCIS)-certified, cloud-based server can provide centralized UID
generation, management and storage, as well as ensure interoperability with manufacturing and business systems.
The cloud-based server is the central communications
hub for supply chain partners and provides mobile connectivity, so product authentication can flow all the way
down to the consumer level via tablets or smartphones.

>> VIDEO:

Serialization Leads to Optimization

In this video, Rockwell Automation Solution Manager

Joe Whyte explains the various steps in the Rockwell
Automation holistic serialization solution. He also
discusses the importance of real-time data visibility,
aggregation, and how that can be used to optimize a
business in several key areas.

Other Considerations

Given the global nature of most pharmaceutical supply

chains and the varying nature of serialization programs
from one country to another, global support can be crucial to ensuring real-time and local-language assistance
is available should an issue arise.
Some manufacturers might also benefit from remote
support services, which can help reduce the burdens
placed on plant staff and be more cost-effective than
transporting technicians from site to site. These services
can include real-time, application-level support of serialization systems, remote-asset health monitoring and
network design services.
Its also important not to forget the silver lining of a
comprehensive and holistic serialization system: Greater
supply chain integrity offers more than compliance.
It also can deliver reverse-logistics benefits and more
t Previous page

Watch the video now!

accurate and efficient recalls, and provide valuable data

for improved forecasting and more customer-specific
marketing programs.
Therefore, as you begin implementing serialization
systems, dont only focus on what the system must do.
Start thinking about what the system can do.
Learn about Rockwell Automation Serialization Solutions.
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OEM PROFILE: OEM HELPS CUSTOMERS

BY USING CLOUD-BASED SOLUTION
Cloud-enabled remote monitoring solution allows Premier Tech Chronos to optimize machine performance with deeper insight into equipment and diagnostic information.

>>

Innovation has been a primary business

driver for the industrial equipment group
of Premier Tech Chronos (PTC) since its founding in
1989. Headquartered in Quebec, Canada, the company
is a Rockwell Automation Machine Builder Partner
that delivers bag packaging equipment and complete
end-of-line packaging solutions. The companys product
portfolio meets both rigid and industrial flexible packaging requirements for diverse applications worldwide.
Recently, the company asked Rockwell Automation to
help improve the maintainability of its SPLX Compact palletizer. PTC standardized on Rockwell Automation control
and information solutions in 2001 and collaborates with
the company on machine system designs.
The compact model saves about 30% in length and 20% in
width. The completely automatic machine palletizes up to 50
cases per minute, depending on size and stacking patterns.
Our SPLX Compact palletizer leverages the functionality of our popular SPLX models in an even smaller
t Previous page

footprint, explains Chakim Belrhali, marketing manager,

PTC. Its an ideal solution for applications that require
high throughput rates with minimal floor space.
The compact models control system is based on the
Allen-Bradley CompactLogix controller, Allen-Bradley
PowerFlex 525 AC drives, and PanelView Plus 6 graphic
terminals. For machine safety, the system incorporates
Allen-Bradley safety light curtains and Allen-Bradley
Guardmaster safety relays. The information-enabled palletizer is integrated on an EtherNet/IP network.
Over the years, weve relied on the scalability of the
Rockwell Automation platform to optimize the performance of all of our machines large and small, Belrhali
says. Now we turned to the company to help us improve
our ability to monitor our equipment in the field. While
PTC prides itself on its customer support, much of their
aftermarket services were reactive in nature.
Typically, a customer would alert us to a performance
issue, and we could access their equipment online and
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the people who need it. In addition to triggering proactive maintenance activities, the system also can provide
users with required part numbers and even fulfill a part
order and schedule the required maintenance.
The solution is engineered to modular cloud information integration (MCCI) standards and powered by Microsoft Azure cloud services, which stores and processes
the collected data. Microsoft is a Rockwell Automation
Strategic Alliance Partner.
Exceptionally flexible and scalable, the MCCI system
can be configured to an end users security standards
and data collection preferences and priorities. For PTC,
the cloud-based system means they can provide their
customers with an optimal level of aftermarket service.
Now, our customers will be able to monitor equipment
parameters both on the plant floor and through mobile
technology, Brochu says. And we will be able to offer
equipment monitoring services designed to better maintain the health of their machines and improve overall
performance.
Rockwell Automation OEM Partner Premier Tech Chronos
provides design, manufacturing and marketing of state-of-theart industrial equipment. It offers solutions for the packaging,
recycling and processing of a range of organic and non-organic
materials in various industries, such as horticulture, construction, aggregates, food and agriculture.

The most important outcome of a

cloud-based solution is making
relevant data quickly and
easily accessible to
the people who need it.
troubleshoot the problem, notes Louis Brochu, engineering aftersales manager, PTC. But we wanted to provide
a service that would be more proactive and better
maintain the health of their system.
Working with Rockwell Automation, PTC developed
a cloud-enabled remote monitoring solution that could
be applied to the SPLX Compact palletizer and to all the
companys equipment. Using the cloud-based software
platform, the wireless solution allows PTC to share
vital diagnostic information with customers to enable
predictive and preventative maintenance activities. It
also provides PTC customers with mobile access to
machine status.
Through the cloud-enabled solution, we can continuously monitor a wide range of performance parameters
regarding machine components and overall cycle times,
Brochu says. Based on the results, we can determine the
optimal time for maintenance, and also improve overall
equipment effectiveness [OEE].
The most important outcome of a cloud-based solution
is making relevant data quickly and easily accessible to

Learn more about Rockwell Automation OEM Partners.

Free On-Demand Webinar

Wireless for Industrial Operations

Deploying a wireless network requires thoughtful planning and design.
It also takes periodic monitoring to meet expectations for bandwidth, throughput,
reliability and security.
This free on-demand webinar provides a technology overview to help you begin
successful WLAN design and implementation that meets performance requirements
of industrial control applications.
Topics include:
Wireless Nomenclature
Client Types
WLAN Architecture Types

Unified vs. Autonomous Architecture

Industrial Control System
Application (ICSA) Recommendations

Visit http://goo.gl/wrjXi1 anytime or click to view this 15-minute webinar now!

Watch it whenever you want, on your schedule!

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ARE YOU MANAGING YOUR NETWORK

SECURITY RISKS?
Learn 10 steps to help protect control systems on a standard network, and find out what
Rockwell Automation network security solutions are designed to help.

>>

As organizations look to leverage modern

technologies with goals of improving their
operational efficiency, industrial networks must be
designed with the ability to provide seamless flow of
information from control devices to enterprise systems.
The emergence of these increasingly connected systems
places a greater demand on design, focusing on robust,
fast, available and secure solutions.
Rockwell Automation takes a holistic, systemsoriented approach to industrial security by providing
expertise, products and professional services that help
companies proactively assess and address potential
security risks throughout their system.
Using a defense-in-depth security approach, we
can help address internal and external security threats.
This approach is based on implementation of multiple
layers of security using both technical and nontechnical solutions that allow you to mitigate both malicious
and unintentional security threats.
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Here are some ways we can help you secure your

control system while you continue using a standard
network and modern technologies.

Solutions for Improved Security

1. Remote Access. Do you need to communicate with

a control system over a nonproduction network, such as
public or business networks? The Stratix 5900 Services
Router helps protect information by using encryption
technology, permitting access to authorized users while
still using the existing untrusted network.
2. Unauthorized Access. Have you ever lost production because someone made a change they werent
supposed to make, such as downloading a program to
the wrong controller? FactoryTalk Security can help
control the extent to which users can interact with
controllers.
3. Intellectual Property Protection. Are you worried that your machines could be duplicated by your
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competitors? Logix Source Protection, a feature in

Studio 5000, enables users to assign a password to
any Routine or Add-On Instruction (AOI) to protect
valuable intellectual property contained within the
applications.
4. Outside Hacker. Have you experienced performance issues or suspicious network traffic and suspect
malicious activity, such as malware or a virus? Enforce
network segmentation and policy with the use of
Stratix 5900 Access Control Lists and firewall features
ensuring only authorized users and appropriate traffic reach your control system assets.
5. Unauthorized Changes. As a machine builder,
have you ever been suspicious that your customers have
made changes they werent supposed to make? As an
end user, have there ever been changes made to your
system that went undetected for a long time? The Controller Change Detection in Studio 5000 can help you
detect changes quickly to determine if any unauthorized modifications were made to your code.

2. Ensure robust and reliable operations by limiting and managing network traffic through the use of
firewalls and intrusion detection/prevention systems.
3. Protect PC assets by using anti-virus and application white-listing. Reference material: Achieving Secure,
Remote Access to Plant-Floor Applications and Data,
Publication # ENET-WP009.
4. Establish a system patching policy to keep software up to date. Reference material: Computer System
Security Updates, Publication # SECUR-WP002.
5. Develop security policies to manage the human
factor, such as managing and protecting passwords,
and managing removable media and use of personal
devices.
6. Implement a level of physical control by putting
the key-switch on your Logix controller in Run Mode.
7. Control who is allowed to do what from where in
the application with FactoryTalk Security.
8. Monitor your system with Controller Change
Detection and FactoryTalk AssetCentre.
9. Protect your intellectual property with Logix
Source Protection.
10. Limit access to automation equipment by
implementing physical controls such as locking
cabinets and doors.

10 Actionable Steps

In addition to the previous suggestions, you can further enhance your industrial reliability and security
with these 10 actionable steps.
1. Control who has access to various areas of your
network by using features such as access control lists
and port-blocking features.
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Learn more about Rockwell Automation Industrial

Automation Security Solutions.
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ADDITIONAL RESOURCES
Click on the resource below to access it.
ROCKWELL AUTOMATION FOOD & BEVERAGE BEST IN CLASS GUIDE
ROCKWELL AUTOMATION AGILE FOOD PRODUCER WHITE PAPER
VIDEO: SMART SOLUTIONS FOR THE FOOD AND BEVERAGE INDUSTRY
ROCKWELL AUTOMATION SERIALIZATION SOLUTIONS
THE CONNECTED ENTERPRISE EBOOK
THE CONNECTED ENTERPRISE MATURITY MODEL
INDUSTRIAL AUTOMATION NETWORK SECURITY GUIDES
WHITE PAPER: RETHINK WHAT YOU SHOULD EXPECT FROM YOUR DISTRIBUTED CONTROL SYSTEM
ROCKWELL AUTOMATION OEM GUIDE TO BUILDING BETTER MACHINES

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Visit Our Library of Free On-Demand Webinars About

Industrial Automations Hottest Topics

Free on-demand Fundamentals Series webinars hosted by The Journal from Rockwell Automation and
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Wireless for Industrial Applications

Understanding PLC-Based Stepper Motion Control
An Introduction to Virtualization
Remote Monitoring, Programming & Asset
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Manufacturing Velocity: Position Your Operations
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Lifecycle Extensions & Migrations

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