ALPS Inspection is modernizing its non-destructive testing systems with an IoT solution from EXOR, a specialist in digital industrial applications. To achieve this, the company upgraded its existing technology and replaced an outdated controls platform. The combination of HMI, cloud, and edge technologies increases transparency through real-time data and reduces the need for costly on-site service visits through remote maintenance.
The challenge: Manual testing processes lead to high service costs
ALPS machines inspect plastic containers for leaks, for example in the chemical and food industries. Faulty products can have serious consequences, such as leaking detergent bottles or defective chemical containers. Therefore, these inspections must be highly reliable and performed in real time within the production lines.
Before introducing IoT-based remote maintenance, there were no automated mechanisms to immediately detect and document errors. Many processes had to be done manually, which made them time-consuming Data access was also limited. Production counts, material flows, and inspection values were not organized in a structured way or made available for analysis.
In addition, ALPS operates thousands of machines worldwide that perform billions of tests each year. The company therefore requires remote capabilities to monitor and maintain its systems regardless of location. Previously, service technicians had to travel to the machines to diagnose issues. For customers, this resulted in longer downtimes and high service costs.
The challenges at a glance
- Manual inspection processes without real-time analysis
- High service costs due to on-site maintenance
- Lack of transparency regarding machine status
- Limited interfaces for integration
The solution: Modernized inspection systems with new HMI, IoT technologies, and cloud connectivity
The solution developed by EXOR and ALPS combines modern hardware, flexible software, and connected cloud technology for remote maintenance. ALPS uses EXOR’s HMI platform to modernize its existing control systems and enable remote servicing. The integration of the JMobile development environment with EXOR’s JSmart HMI hardware and the Corvina IoT platform provides a complete solution that meets all of ALPS’ operational requirements.
JSmart: Industrial-grade HMI tablet
JSmart is an industrial tablet with integrated Wi-Fi that can be mounted directly on machines without the need for an additional control cabinet. It offers a robust and flexible user interface that simplifies everyday operations in production.
Key features:
- 32-bit RISC dual-core or quad-core CPUs
- 10/100 Ethernet port with PoE (Power over Ethernet)
- Capacitive multi-touch screen up to 1920×1080 pixels
- Built-in Wi-Fi interface
- Motion and environment sensors
- IP67 protection rating
JMobile: Data acquisition and visualization at the machine
The HMI hardware runs the JMobile software, which provides functions for visualization, remote maintenance, and data acquisition. It collects data directly at the machine, displays it graphically, and compiles it into reports. One particularly important feature is the diagnostic report. The twelve-page PDF can be generated directly on the HMI and provides a precise overview of the machine’s condition.
Key JMobile features at a glance:
- Client-server architecture with web technologies and JavaScript engine
- Integrated OPC UA server/client and MQTT publisher
- Support for PLC functions
- User-friendly environment with widgets and macros for HMI applications
- Encryption of all data and connections
- Time and action scheduler for remote maintenance
Corvina Cloud: IoT platform for remote access
Corvina Cloud complements the solution with an IoT platform for remote access and data management. Technicians can retrieve real-time data from machines anywhere in the world and analyze faults remotely. Customers simply need to connect their HMIs to the internet.
The cloud solution is an open, cloud-based IoT platform for industrial use that provides all the necessary technologies. It serves as a container for distributed edge systems and integrates data acquisition, monitoring and control, configuration management, built-in web tools, and programming environments. It connects IT and OT architectures and includes tools such as asset performance management and remote maintenance.
Open interfaces for flexible integration
A key success factor is the openness of the platform. Data can be exported in various formats and integrated using standards such as OPC UA, SQL databases, or CSV files. Protocols such as MQTT and open-source solutions are also supported. With this solution, real-time data is not only collected but also used for process optimization. Production parameters can be adjusted more precisely, and machine performance is improved. Real-time visualizations provide technicians with valuable insights and enhance process control.
With this infrastructure, machine analysis during remote maintenance becomes significantly faster since all relevant information is immediately available. This eliminates the need for many on-site service visits and leads to substantial cost savings.
Partnership with EXOR
The partnership with EXOR played a key role in the project’s success. EXOR contributed its expertise in hardware development and in delivering complete IoT solutions. The combination of JSmart, JMobile, and Corvina resulted in a modular system that can be expanded flexibly. Future developments such as artificial intelligence and machine learning will be easier to implement as a result.
The result: Added value through data, remote maintenance, and future technologies
The partnership between ALPS Inspection and EXOR demonstrates how the combination of hardware, software, and cloud technology is transforming quality assurance in production. A key benefit of the solution lies in the newly established data foundation. Production figures, throughput rates, and test data are automatically recorded and made available in real time. This enables monitoring of production quality, optimization of processes, and identification of weak points. Automated PDF reports simplify information sharing and provide a clear picture of the machines’ condition.
Looking ahead, ALPS and EXOR are focusing on artificial intelligence and machine learning. However, traditional HMIs do not offer sufficient computing power. Under the name MicroEdge, EXOR is developing new devices that provide the necessary processing performance directly at the machine. This makes it possible to filter and analyze large volumes of data directly at the machine, gaining insights instantly and without detours.
Summary of Results
- Real-time data enables precise process optimization
- Remote access reduces costs and downtime
- Automated reports create transparency
- Open platform allows flexible expansion
