Industrial Safety Solutions Resources

Safety and Productivity Solutions

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Paper Mill Migrates to Modern DCS

For this paper mill, migrating its batch digester to a modern DCS offered significant improvements in yield, quality and operator efficiency.

Drive Out Distortion With a Low-Harmonic Drive

Drives with built-in distortion mitigation help protect process integrity and uptime in water/wastewater operations.

Copper Smelter Goes All In on a Modern DCS

ENAMI needed a modern control system with strong diagnostics, easy maintenance, and data management to support business decisions and operational improvement.

Are You In Break-Fix Mode With Your Machines?

Three priorities will help you justify migration: operations, finances and corporate strategy. And there’s another factor to consider: employees.

Using a VFD With Synchronous Capabilities

Using a variable frequency drive (VFD) with synchronous bypass and transfer capabilities can yield significant cost savings.

AC Drives Give You a Countdown to Downtime

New AC drives learn how they’re being used and adapt to changes. This allows you to see their predicted life down to the hour to reduce unplanned downtime.

A Unified Solution for Measurement and Control

Improve measurement and control with a unified solution for multi-well pad operations.

Is It Time to Digitize Your Lab?

A modern DCS can ease technology transfer – and help speed life sciences products from pilot plant to market.

From "Washdown" to "Hygienic Design"

Collaboration between CPG manufacturers and OEMs helps unify processing and packaging applications – and eases the way to compliance.

AngloGold Modernizes with a New DCS

AngloGold chose a modern DCS for its activated carbon process facility. Their operators quickly transitioned to simpler ISA 101 compliant grayscale displays with increased visibility.

Gain Flexibility with Modern Batch Systems

The utilization of a modern batch control systems helps chemical producers achieve more flexible, productive and efficient operations.

Serving Up Value By Controlling F&B Processes

Food and beverage manufacturers can use model predictive control to create a standard model for production, optimizing capacity while maintaining or improving quality.

5 Business Cases for Using AC Drives with Safety

Boost productivity, simplify systems and get better insights into your operations using AC drives that deliver advanced safety over Ethernet.

Outdated Multimodal Port Modernizes with a New DCS

The largest port in central Chile, Los Ventanas, is now also its most modern after a new CEO helped to automate all processes using a modern DCS.

Modernize Your Power System, Boost Productivity

Oil and gas producers are feeling the pain of relying on aging systems. The use of intelligent packaged power cuts risk and costs, while unleashing information for performance improvement.

Gain Better Visibility of Your Plant Operations

Digital technology can transform your maintenance, repair and operations asset data into something you can use.

What Every OEM Should Know About Skid Integration

How to sidestep common roadblocks, minimize engineering time and speed deployment.

Digital Transformation of Mining

Technology is changing the way mining companies do business. Here are five tools you can easily bring online at your mine and quickly see tangible results.

Refinery Proves It’s Too Costly to Not Modernize

A large producer of zinc was facing costly unplanned downtime, exposing them to operational and financial risk. Learn how they overcame these challenges with a modern DCS.

Cement a Competitive Edge with Machine Learning

Cement companies can implement predictive strategies and improve operational performance with machine learning techniques.

Five Steps to Success: DCS Modernization

This approach mitigates project risk – and helps make a more innovative future a reality.

Converting OEMs Speed Development Increase Revenue

Web converting machine builders turn to scalable, flexible IIoT solutions for smart machines that help customers avoid downtime and improve cycle times.

Improve Operator Effectiveness with a Modern DCS

A modern DCS can help novice oil and gas operators perform like your best operators with actionable alarming, predictive insights and a high-performance HMI.

How Distillers Can Increase Optimization

The spirit industry is managing the growing demand by looking to model predictive control to help maximize throughput and efficiency.

Set Yourself Up for Success

How progressive OEMs can differentiate themselves by helping customers meet expectations for highly flexible manufacturing facilities.

How Distilleries Can Maximize Throughput

How can distillers maximize throughput without sacrificing quality or tradition, while also minimizing alcohol loss?

Boost Material Handling ROI via Wireless Solutions

Your automated material handling equipment can help you decrease costs and optimize resources – and wireless solutions can help boost their performance.

Mitigating Risk – Without Applying the Brakes

EV manufacturers are under pressure to expedite their launch schedules. Global program management paves the way for a successful EV launch – and smart manufacturing.

What Will Smart Factories Look Like in 20 Years?

See how today’s new technologies will change how we design, manage and staff operations in a smart factory.

Single-Use Solutions Defy Economies of Scale

Companies are demanding more agile and flexible manufacturing practices in order to meet an industry drive towards more personalised medicines.

Responding to Changing Consumer Trends

The drive for digitalization is accelerating the need for digital manufacturing plants that offer the highest flexibility, combined with reduced production costs.

Make Skid Integration Smart from the Start

Life sciences companies that rely on multiple OEMs can help mitigate skid integration challenges with upfront planning – and a modern DCS.

Migrating Pharmaceutical Processes

Alfasigma decided to migrate its pharmaceutical production solution, but needed to find a suitable supplier.

Stemming the Next Pandemic

At the iBio plant in College Station, Texas, they are leveraging the Rockwell Automation PlantPAx DCS to make vaccine grade proteins from living plants.

Connectivity and Digitization Transform Mining

Three insights into the future of mining based on broad market trends: data, analytics and safety and security.

Chemical Producers: There’s a New Plant in Town

By prioritizing investments around smarter technologies, a connected chemical plant can help you monitor and improve production performance.

Helping an Aging Facility Find New Life

Aging systems at the Pettit National Ice Center meant skyrocketing energy costs. An upgrade would improve sustainability and ice conditions.

Migrate or Modernize? How to Decide

If your plant is aging, you have a choice: migrate specific equipment, or modernize to realize the value of new technologies.

What’s Your Integration Strategy?

To create a “facility of the future” that pays dividends for years to come, biotech companies must first take a close look at automation and integration strategies.

Does Automation Take the Craft Out of Brewing?

Learn how craft brewers can automate an existing two to five barrel system to produce more – more consistently, and save money and time.

Three Steps to Better WAGES Performance

Companies can reap the benefits of digital transformation with a strategy that unifies energy and industrial process information to support world-class production.

Where Should My Process Analytics Solution Run?

Producers in the process industries need to answer these three questions to arrive at a viable analytics solution.

Cement Your Profits with Kiln Optimization

Modelling and controlling production with MPC technology can lead to improved kiln stability and overall production rate, reduced material loss, and energy costs.

Approaching Change One Step at a Time

How modern is your mining operation? Connecting your mining operations allows you to gather data in real-time so you can make better business decisions.

Phosphate Plant Reconstructed with a Modern DCS

PCS Phosphate, a chemical processing facility, went through a complete process control migration allowing better and faster decision making capabilities with PlantPAx DCS.

Givaudan Reaps Sweet Rewards of DCS Migration

By partnering with a trusted vendor, companies can more quickly migrate to modern DCS technologies and begin realizing lower total cost of ownership.

Modern DCS Plays Key Role in Mining Efficiency

Modern DCS connects all aspects of a mining operation by bringing together previously independent systems, which allows for greater efficiency and productivity.

One Platform Can Do It All. Process. BMS. EMS.

A strategic upgrade to a single building management, process automation and environmental monitoring platform makes good business sense for life sciences companies.

Successful Alarm Management with Your DCS

Proper alarm management is an ongoing commitment. Discover the steps to modernize your alarm management system.

Gas Processing Optimization Opportunities

Now that the rush to build new gas processing plants has subsided, plants are looking for ways to optimize production.

Don’t Give Up Creativity for Productivity

Now craft brewers don’t have to sacrifice the art of making a small batch brew for the sake of productivity.

Keeping the Craft in Brewing With Process Control

Mother Earth Brewing Co. automated its new brewery with a PlantPAx process control system to ensure repeatability while allowing for the creativity needed for craft brewing.

7 Reasons to Apply S88 Recipe Model to EBR Design

EBR has long been designed through modelling approaches including word processing, proprietary workflow charts and programming-like sequence definition. Why not S88?

The Connected Power Plant

With the proliferation of the Industrial Internet of Things, more power producers are turning to enabling technology, such as a modern DCS, to improve operations.

What Makes for Better Batch Management?

The modern batch approach understands the need of the batch and applies the right technology rather than starting with a technology and trying to use it for all solutions.

Migrating a Legacy DCS: When and How

The risk of a legacy DCS is high. Figure out now when you want to migrate, and how you want to do it.

Reduced Downtime Using Alternative Measures

Alternatives to traditional lockout/tagout procedures offer opportunities for manufacturers to improve worker safety and productivity.

Reducing Safety Risks in the Oil and Gas Industry

Oil and gas extraction is one of the highest-risk category industries. Make sure you're doing all you can to increase the safety of your workers and equipment.

Bausch + Lomb at ARC Forum Echoes Automation Fair

Bausch + Lomb upgrades to a modern distributed control system (DCS) with minimal downtime, enhancing functionality.

Food and Beverage Packaging Machine Safety

New technologies offer important machine safety solutions, yet the packaging line still has numerous areas where manufacturers must consider the setup of a plant.

Automating to Reduce Food Production Costs

Food and beverage producers use automation to improve business results in stages: to improve process quality, boost efficiency and achieve the benefits of The Connected Enterprise.

Winter is Coming: is Your DCS Ready?

While the rest of the world raves about the Internet of Things (IoT), the process industries have long enjoyed centralized connectivity as a basic function of the DCS.

Are You Modeling the Impact of the Human Element?

What factors should be included in the probability of failure on demand calculations of safety instrumented functions?

Managing Obsolescence in Offshore Oil and Gas

Managing obsolescence is not about taking the whole process offline. But to get the maximum performance and reduce the risk, there is much that can be done if you take the right approach.

Must Devices Be Certified for Use in SIS?

The certification of devices in a safety instrumented system is meant to verify the performance by measuring the failure rate data. Still, failure rate data comes in many different forms.

Why You Should Have Workflow Approval

As process engineers, we see lots of cases where having ultimate control of our process is not only desired, it's critical.

My Two Passions are Motorsport and Oil Rigs

We are all limited by budget but would like better equipment, faster response times, more operator-friendly interfaces and a safe and reliable system.

Scary SIS Audit Findings

The ISA 84 (IEC 61511) standard on safety instrumented systems (SIS) in the process industries requires audits. Interested in some horror stories?

Why Recipe Versioning Makes Sense

If only there was an effective system to help ensure that managing and tracking recipes can be done easily.

How Secure is Your Recipe IP?

Making sure recipes are secure has become a very important issue and is a valid concern that spans many industries.

Can You Operate an Underwater Oil Field Safely?

There is a wide array of technology deployed all over the world that can help support the subsea operations in a safe and productive way.

Strategy for Dealing With the Falling Oil Prices

If only people in the industry knew when the price of oil was going to rise, and to what price.

Are Your Tire Curing Presses Struggling?

A strategy based on The Connected Enterprise can breathe new life into existing equipment - and accelerate productivity.

When Brewing Beer, Small is Big

The popularity of craft beer fits very well into modern manufacturing techniques.

Increasing Productivity in a Changing World

How do stay ahead of competitors despite food industry fluctuations.

Design-Build Selection for Water Utilities

The right procurement methodology could be the key to a cost-effective, future-ready water system.

Savings and Distributed Control System Migrations

Is the current control system for your food or beverage operation causing unnecessary maintenance time and costs?

Safety First in a Changing World

Downtime costs money, safety events can cost much more. Is it time to review or upgrade your safety system?

New Safety Standards in 2016

Two key standards for electronic machine control (EN) ISO 13849 and IEC 62061 will be merged into one: ISO/IEC 17305.

Skills Gap Still a Major Industry Concern

Automated control platforms can unite various systems over a large geographic area, helping you address staff shortages and high staff turnover.

Renewables Help to Fulfill Demand for Power

Growing energy demand and a tightening of access to conventional supply are making the renewable energy industry commercially viable.

Seven Steps to Build Serialization-Ready Machines

Upgrading a plant's control infrastructure can be a cost-effective decision to get the most from capital equipment improvements.

Seven Steps to Build Serialization-Ready Machines

To combat counterfeiting, pharmaceutical manufacturers are putting serialization processes in place.

The Future of Food and Beverage Manufacturing

There are two trends in the emerging and mature food and beverage markets that are driving the need for optimization

The Potential for Natural Gas Market Convergence

How could developments in natural gas markets support a more integrated market with more consistent pricing?

Process Engineers: Nobody Does It Better

The process industry has changed in line with consumer, economic, globalization, information, safety and energy demands.

The Four Ms of Food Manufacturing

With high complexity and low margins, it often pays to take a simple approach to food and beverage production and ensure you're performing at optimum levels.

Oil and Gas Automation: From Sci-Fi to Subsea

Automation in extreme environments used to be the stuff of science it's closer than you might think! Especially for the oil and gas industry.

Three Key Components to Manufacturing Velocity

The automotive industry needs to address manufacturing velocity in order to respond to customer demands around the world more quickly and get to market faster.

The Human Touch in Automated Food Production

Despite being an automation-led sector, the food and beverage industry is a massive employer, representing 15% of the overall manufacturing workforce.

Maintenance Specialists on Process Optimization

Maintenance technicians have seen their profession evolve. So have metrologists. Yet, both functions can benefit in working in closer collaboration.

Why Flexibility in Production is Driving Growth

Mass production changed the face of the manufacturing industry, making it possible to produce more items of the same size and specification, and market them on that basis.

Food Production: Defining an Upgrade Strategy

Logic dictates that technology-driven manufacturing is the way forward, but creating your ideal infrastructure for 2020 will require you to define a workable upgrade strategy.

Mining of the Future with Technology of Today

Rockets, asteroids and enormous profits. How close are we really to mining asteroids for minerals, water and precious metals using methodologies widely used in mines across the globe.

Food Production: A Taste of Things to Come

If you could create your ideal manufacturing plant, what would it look like?

What is Left for the DCS Market?

During the past 25 years, as the performance of automation controllers has increased, suppliers of Distributed Control Systems (DCS) have lost market share.

Historical Data Isn't Enough for Your Operation

Relying solely on historical data to decide future actions is rear view mirror driving. Vital information as it is, it's not enough for the modern manager.

TÜV Accreditation: What Does It Mean?

Looking at it from a professional perspective, I consider TÜV accreditation to be essential if you are going to try to teach or sell safety concepts to other people.