Summary
Key results
A foundation for digital twin – ready architecture and infrastructure
Standardization and scalability – a model ready for rollout across additional plants
The need for standardization and production development within the Industry 4.0 framework
The implementation of the Industry 4.0 strategy required Pfeifer & Langen to undertake specific transformation initiatives. A key challenge was standardizing the way data was collected from machines, cameras and Operational Technology (OT) systems. At the same time, the company needed to ensure reliable real-time data transmission and its centralization in the cloud in the form of a scalable data lake. To enable further development of digital initiatives, it was also necessary to prepare the infrastructure for future automation and advanced analytics.
As part of the adopted strategy, Pfeifer & Langen selected the Litmus LoopEdge platform as the edge computing layer and AWS as the target cloud environment for production data. However, project execution required a partner capable of combining expertise in OT/IT integration, data architecture and cloud environments.
Sii Poland was chosen to deliver the project due to its experience in industrial initiatives, competencies in edge computing and data flow architecture and its ability to design and implement a scalable solution aligned with the Industry 4.0 objectives.
Launching the digital transformation within the Connected Factory model
The project delivered by Sii experts in collaboration with the client’s team constituted the first phase of the Connected Factory program and included, among others:
- Connecting OT devices (PLCs, sensors, ABB and Zeiss systems)
- Integrating smart cameras (Woodpecker IoT Camera)
- Building a data flow architecture: sensor → edge → cloud
- Streaming video and images to AWS Kinesis Video Streams
- Data normalization and tag management
- Developing containerized applications running at the edge layer
- Configuration and testing of two factories: Glinojeck and Könnern
The project was executed in phases. Following ramp-up and environment configuration, the Glinojeck factory was connected first, integrating ABB PLC controllers, sensors and cameras, followed by the Könnern plant. The next step involved optimizing data flows and validating the correctness of integration in both locations. The project concluded with acceptance testing using real and simulated data, confirming the solution’s readiness for further scaling within the Connected Factory program.
Digital production ready for further development and automation
Sii’s collaboration with Pfeifer & Langen on the Connected Factory project marked a significant step toward production digitalization and the implementation of Industry 4.0 across the company’s European sugar plants.
Sii specialists delivered a complete architecture and an operational infrastructure for collecting and transmitting data from factories, forming the first stage in building a digital twin of the entire production process. The integration of OT systems, smart cameras and data centralization in AWS established a consistent edge-to-cloud data flow model.
As a result, the company gained real-time access to machine data, video streams from production lines and a centralized AWS Data Lake environment enabling ongoing analysis.
The project was delivered using Litmus LoopEdge technology, which was new to the client, while ensuring compliance with the adopted architecture. Sii was responsible for the full implementation of the solution, its configuration, necessary adjustments and training of the client’s team.
A significant challenge was the solution’s sensitivity to performance and latency, including tag readings every 100 ms, data transmission to the cloud every second (ABB PLC, Zeiss NIRS) and video streaming under variable network conditions. In response, the Sii team optimized Node-RED data flows, prepared performance reports and transmission adjustments and implemented buffering and data replay mechanisms to ensure system stability and reliability.
The designed architecture enabled the standardization and scaling of the Connected Factory model to additional production plants. The data collected as part of the project later became the foundation for the client’s R&D initiatives in areas such as raw material quality analysis (beets, juice and sugar), automated process decision-making and predictive maintenance.
Thanks to the involvement of Sii teams, Pfeifer & Langen gained not only a fully operational technological infrastructure but also a structured and scalable data architecture forming the foundation for further development of the digital twin and subsequent automation initiatives within the Connected Factory program.
Key results
- Foundation for a digital twin – architecture and infrastructure enabling further solution development
- Full visibility into production data – access to machine data and video streams centralized in AWS with real-time analytics capabilities
- Standardization and scalability – a Connected Factory model ready for rollout across additional plants
- Faster diagnostics and automation potential – data leveraged in R&D projects, including quality analysis and predictive maintenance