The new PET blow molding machine of a beverage manufacturer could not be integrated into existing IT systems. An IoT-based retrofit provided the solution, without modifications, with end-to-end data availability and high security. This shows how machines with proprietary control systems can be seamlessly digitized, even in sensitive production environments.
The expert for this is Perinet GmbH, which implements an end-to-end infrastructure from the field level to IT (including the cloud) based on standards. This allows for direct, smart, and secure integration of sensors and actuators with the cloud, the internet, and company IT.
The challenge: No interface, no data
A multinational soft drink manufacturer wanted to integrate its new PET blow molding machine into an existing IT and production environment. The machine forms plastic bottles from PET preforms by heating them and shaping them under pressure.
The new machine has a proprietary control system and no digital interface. As a result, it cannot work with the Manufacturing Execution System (MES). The manufacturer was therefore looking for a simple connection to the MES. Perinet GmbH, together with its development partner Zentinel NDS, developed a modern and efficient IoT solution that meets two criteria:
- It integrates fully into the existing systems.
- It requires only minimal intervention in the existing infrastructure.
Challenges at a glance:
- No digital interface on the new machine
- Proprietary control prevents system integration
- Manual data collection causes errors and delays
- Lack of transparency hinders analysis and optimization
The solution: Retrofit without interfering with the control system
The IoT solution from Perinet and Zentinel NDS continuously records energy consumption, utilization, and cycle times without interfering with existing control systems. It operates independently of the machine architecture and processes operational data in a structured way. The solution integrates seamlessly into existing production environments and is designed for future requirements.
Modular architecture for smart manufacturing
The implemented concept combines two different IoT adapters, an edge server, and Single Pair Ethernet (SPE). The architecture is designed to be scalable, so additional machines or sensors can be easily integrated, even as production volumes grow.
ZentNodeCT
This robust IoT adapter captures production data directly at the machine, including the number of incoming PET preforms, the finished PET bottles, and level signals at the machine’s output that indicate a blockage. The adapter automatically calculates maximum, minimum, and average values in user-defined time intervals and transmits this data via the MQTT protocol to downstream systems.
ZentNodeIO
This industrial adapter uses 24V DC signals for remote monitoring and control of production equipment. It enables bidirectional communication between machines and higher-level IT systems via the MQTT protocol. For example, it can capture signals from material level sensors, signal lights, or operating indicators.
ZentEdge server
This rugged edge computer collects, stores, and processes machine data from the ZentNode adapters. All captured information is aggregated, processed, and written to an SQL database. The database is directly connected to the MES system, allowing production data to flow into IT systems without detours.
Single Pair Ethernet (SPE)
This Ethernet variant handles communication between the individual components. It enables data transmission at 100 Mbps and power supply over a single cable, which significantly reduces installation effort. SPE eliminates the need for complex gateways and allows industrial devices to be integrated into IT networks via standard protocols such as HTTPS and MQTT or a REST API. All data transmission is also encrypted with TLS.
Data on demand and in real time
The Perinet solution fundamentally changes the operation of the PET blow molding machine. The system is ready for use immediately and operates reliably without significant downtime. No modification of the machine is necessary, as external adapters and a secure edge infrastructure capture all relevant data.
The collected data is available in real time, providing precise information on production volumes, machine utilization, and potential disruptions. This simplifies daily operational monitoring and creates a foundation for systematic analyses of optimization potential. Cross-site benchmarking between shifts or plants also becomes easier.
Ready for use in other industries
The IoT solution connects systems without interrupting production or interfering with machine control. These characteristics make it attractive for various industries.
In the food industry, the IoT solution collects production data from beverage or canned food filling lines. A pilot project in Spain showed how skilled staff could quickly integrate existing machines without interruption.
- In the pharmaceutical industry, the solution can securely integrate packaging machines into IT systems. Data security and traceability have the highest priority in this sector.
- In the automotive industry, the solution records production figures in assembly lines and monitors quality during assembly. The collected data improves traceability and provides a foundation for continuous optimization.
The result: Future-proof through standardized IoT components
The digitization of the PET blow molding machine demonstrates how operational technology (OT) and modern IT systems can work together effectively. With standardized IoT components, existing systems can be easily integrated into digital environments. Implementation requires no deep interventions in OT, and production processes remain stable. The IoT solution meets all requirements for data security and traceability, which are becoming increasingly important due to legal and regulatory demands.
The system from Perinet and Zentinel NDS adapts to new production requirements, enabling continuous data integration from sensor to IT system. Improved data availability facilitates operational decision-making as well as medium- and long-term planning. Beyond the benefits for ongoing operations, this also opens new possibilities for maintenance strategies, such as using historical data for preventive maintenance. This makes the solution a long-term, sustainable foundation for further digitization initiatives.
Key outcomes at a glance:
- Real-time data access without machine modification
- Seamless integration into existing MES systems
- Improved monitoring and easy benchmarking
- Modular, scalable architecture for further applications
