Case study · Industry
One on-site platform for a food processing plant's machines, energy and security
The challenge
The plant runs process machines that need tight, provable conditions, on a site powered by grid, generator and a large hybrid solar system.
Its information was spread across machine panels, standalone thermostats, inverter apps and a separate CCTV recorder. Nobody could see the whole picture in one place. Records needed for compliance had to be pieced together by hand.
The owners wanted all of it on site, under their control, and working even when the internet didn't.
What we built
Machine data and control. We collected live data from the processing machines and their controllers, logged every key parameter, and brought supervisory control onto one screen. Existing machine safety logic stayed where it belongs, in the machines.
Environmental monitoring. Temperature, humidity, CO₂ and air-quality (AQI) sensors in the process and storage areas, plus smart thermostats, all logged continuously, with alarms when conditions drift.
Energy and hybrid solar.
- Telemetry from a multi-inverter hybrid solar system, battery storage, the generator and the main energy meter, on one energy dashboard.
- During commissioning we verified meter wiring and readings (CT orientation, phase mapping).
- We ran a formal stability and acceptance test before sign-off.
Security integration. The plant's NVR and cameras are integrated into the same platform, so events and alarms line up with what the cameras saw.
OT security. The plant network is segmented from the office and internet, with controlled remote access and least-privilege accounts for the operational systems.
Data integrity and compliance.
- Timestamped, tamper-evident records
- Controlled user access
- Backups
- Exportable reports, so the plant can show what happened, when, and who changed what
How it runs
How the system is layered:
- Field devices: machines, sensors, inverters, meters, cameras
- Gateways
- The on-site Ultra Edge core
- Dashboards and alarms (local screens, plus secure remote access)
The core keeps controlling and logging even when the internet is down.
What the client has now
- One view of machines, environment, energy and security instead of five separate systems
- Alarms that reach the right person, instead of noise on a panel
- Audit-ready records for compliance
- Clear visibility of solar, battery, generator and grid behaviour
What happened next
The same client asked us to automate their newmushroom farm in Punjab.Read the farm project →
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