In the context of increasing regulatory demands and consumer expectations, traceability, safety, and efficiency have become crucial challenges in the food industry. ICP DAS addresses these needs with a fully integrated monitoring solution, recently implemented in a Taiwanese food factory, aimed at optimizing production traceability and improving operational control.
Centralized scada-based monitoring
Previously, the factory operated with independent systems for weighing, temperature control, and overflow detection. These siloed architectures hindered real-time supervision and delayed data consolidation in the event of food safety issues.
ICP DAS’s solution leverages the AVEVA Edge SCADA platform to unify the data streams from multiple sources, making centralized supervision possible across the production chain.
Products featured in the ICP DAS Monitoring Solution
- PDS-734 – Serial-to-Ethernet Communication Server
- WISE-7144 – Intelligent Remote I/O Module for Overflow Detection
- MDC-711 – Modbus Data Concentrator for Environmental Monitoring
- uPAC-7186EX – Programmable Automation Controller for equipment monitoring
- ACS-11-MF – Access Control System with RFID card reader
These modular components enable seamless communication and control across existing systems while supporting future expansion.
Core components and their roles
- Powder Weighing System : Utilizing the PDS-734 Serial-to-Ethernet server, legacy PLCs managing weighing operations are integrated into the factory network. This enables real-time monitoring of raw material usage, essential for batch consistency and recipe compliance.
- Oil Tank Overflow Detection : The WISE-7144 I/O module provides instant alerts in case of overfilling, ensuring compliance with safety standards and reducing material waste.
- Environmental Control : The MDC-711 Modbus Data Concentrator gathers temperature and humidity data from distributed sensors. This is especially useful in temperature-sensitive processes, such as storage or fermentation. Meanwhile, the uPAC-7186EX controller monitors equipment in the control room, contributing to predictive maintenance strategies.
- Access Control Management : The ACS-11-MF card reader ensures that only authorized personnel can access critical zones (e.g., clean rooms or raw ingredient storage), reinforcing GMP (Good Manufacturing Practice) compliance.
Use cases and application scenarios
This modular and scalable architecture can be applied to a broad range of food industry environments:
- Batch Traceability & Compliance : The system generates automated production logs, facilitating traceability for audits, recalls, or certifications (such as ISO 22000 or HACCP). This drastically reduces the time and effort needed for compliance reporting.
- Process Optimization : By aggregating weighing data, environmental metrics, and access logs, the factory can analyze inefficiencies and fine-tune operations—whether that means balancing material usage or adjusting environmental parameters for product quality.
- Incident Response & Food Safety : With real-time alerting on abnormal conditions (e.g., tank overflow, high humidity), corrective actions can be taken before a minor issue escalates into a major food safety incident.
- Remote Supervision & Maintenance : Thanks to web-based access, factory managers and technicians can monitor and control the system remotely, minimizing downtime and enabling proactive intervention during off-hours.
A scalable template for digital transformation
This case demonstrates how legacy equipment in existing factories can be transformed into Industry 4.0-compliant environments without full hardware replacement. The modularity of ICP DAS solutions allows food manufacturers of all sizes to deploy a phased digital transformation strategy tailored to their needs and resources.
With its strong expertise in industrial automation and technical consulting, IPC2U plays a key role in deploying ICP DAS solutions within demanding environments such as food manufacturing plants. As a trusted partner, IPC2U provides tailored advice, selects the most suitable equipment, and ensures full support for integration, SCADA module configuration, and network connectivity. This customized approach enables industrial players to rapidly benefit from a reliable, connected, and scalable system, ensuring enhanced traceability and long-term compliance with food safety standards.
