A leading chocolate manufacturer in Pennsylvania needed a manufacturing execution system to tie together 9 different business systems into a single software package. This included customer order management, shipping and receiving, warehouse management, track and traceability, SPC, and in-process inventory tracking. Corso delivered a solution with Inductive Automation’s Ignition platform and helped take the company to the next level.

10 Torr Distillery and Brewery in Reno NV needed an automation system for their new facility. The system consisted of an automated grain dispensing line, 2 Mash systems, 14 fermentation tanks, a canning line, a glycol chilling system, a stripping still, and the highlight of the operation, a 28’ tall Vacuum Still with a gin basket used to produce all of their spirits. In addition to beer and various spirits, they also produce canned cocktails with flavors developed in house, and canned on their fully integrated canning line.

A leading manufacturer of high-quality, single-source recipe pet food with facilities across North America required a production scheduling management and OEE tracking system for a greenfield Facility. Ignition by Inductive Automation along with the OEE and Scheduling module from Sepasoft was chosen for the SCADA and MES platform, and the required functionality was developed by Corso Systems and tested with various OEM manufacturers on the various production and packaging lines at the facility.

SCS Engineers had been working with the San Timoteo landfill in San Bernadino County California to build out a digital solution for their energy and climate monitoring system. Corso Systems was brought in to develop the system in Ignition, and once the beta for the Perspective Module was released, re-tool the application for mobile devices. This also enabled the system to import a virtual reality interface to display the site topography and equipment information including process data using a VR headset or a Microsoft Hololens.

A leading aerospace company has a production line consisting of multiple furnaces and quench pits capable of heat treating multiple batches of parts at a time. Their current hardware had reached the end of its life and was ready to be upgraded to modern standards. A new manipulator with full servo control, updated safety and interlock logic, and touchscreen operation was made to replace the old unit.

A large oil and natural gas company had been using OSI PI requiring extensive overhead for support. They wanted to be able to better manage and develop the system to meet their needs, including allowing integrator support to get away from a single source of development resources. Canary Labs Historian was the best solution to import 7+ years of data for 1.5 million plus tags, with full data validation and dashboard tools.

Jaxon Energy once again relied on the team at Corso to remodel a previous control system tailoring it for use on a new project. The new facility was a complete overhaul of an existing facility utilizing a control system previously implemented by Corso, and required a control system redesign for a new process used to make renewable diesel fuel from vegetable oils. With total plant control and visibility in mind, Corso wrote PLC logic for system control, designed the HMI screens for operator use and data collection, and deployed a document tracking system for shipping and receiving tracking. RSLogix 5000 was used for PLC logic and control, and the FactoryTalk View suite of software products was used for screen design and various other system controls and alarming.

A cement manufacturing facility worked with us to implement a process historian and data visualization tools for its R&D plant.We completed the work on-site, working directly with the facility personnel to specify the data to be stored in the process historian

A large casino gaming machine manufacturer had an aging conveyor control system and was experiencing an increasing amount of downtime. Increasing issues included productivity losses due to in-process machines being sent to incorrect locations, and a holding and re-work area not functioning correctly.

A leading diatomaceous earth processing facility was storing its production data in Excel spreadsheets. The long-term effects of this method lead to large amounts of spreadsheets on their servers, and made it difficult to access necessary information efficiently. The best remedy for this problem was to move to a web-based solution. This approach provided a centralized database to store the data and an interface for authorized users to enter, edit, and view the data.

Corso Systems implemented FactoryTalk VantagePoint and FactoryTalk Historian to store and analyze process data at multiple facilities for a leading diatomaceous earth processing company.

A diatomaceous earth processing facility worked with us to develop a centralized process change management system. We developed requirements based on their existing system, which was based on Excel spreadsheets. Many of the requirements were designed to provide a robust and automatic approvals process for proposed changes.

Jaxon Energy teamed up with Corso Systems to develop a new control and information system for its Jackson, MS hydrotreating plant. Jaxon leveraged Rockwell Automation's FactoryTalk software suite for robust operator control of the plant and secure remote access to real-time information.

An energy bar manufacturing facility's processing line used eight standalone pieces of equipment with conveyor belts and the speed of the conveyors needed to be synced across all of the machines for optimal operation. The speeds were previously synced by adjusting potentiometers on each piece of equipment leading to unequal speed variations throughout the line. We worked with the staff to implement a PLC-based system with an operator interface HMI to set the speeds for the line, as well as select which speed should be used at any given time.

A diatomaceous earth processing company had two facilities with Wonderware Historian installations on older server hardware. After years of exposure to an extremely harsh environment, the server at one of the facilities catastrophically failed. We were able to recover historical data from the machine and exported it to FactoryTalk Historian. The Wonderware Historian configuration was migrated to FactoryTalk Historian and the data was imported with no loss of data.

Our staff worked with a solar power provider to develop and implement a web-based monitoring system for use at 3 of their new solar power plants. The website was configured to allow internal users to monitor real-time data from each facility, with data access to the general public on a 30 day delay. The system provided operational staff with automatic email and text notifications of equipment alarms. The site included functionality for customer invoicing and utility reporting to comply with regulatory requirements.

Corso met with the SCADA operations team for a large solar power provider to discuss a standardized system built using Wonderware System Platform. The goal was to build objects for the various pieces of equipment at a solar plant, inverters, breakers, power meters, etc., to enable rapid deployment of SCADA systems for new facilities. As part of developing the system, we developed a standardized naming convention for the facilities and all of the data points to allow a script to populate a centralized OSI PI Historian with data from each facility.

Jaxon Energy and Cam 2 International teamed up with Corso Systems to implement a process control and information system for its Vicksburg, MS refinery. Jaxon leveraged Siemens WinCC Open Architecture platform plant operation and secure remote and mobile device access the facility. The control system utilized Siemens S7-1200 PLCs and WinCC Open Architecture, giving Jaxon Energy more power and flexibility than they were able to achieve on any of their existing systems, at less cost.