Process Automation
Telemetry, control and integration for batch, continuous and hybrid process plants - water, food & beverage, chemicals, pharma.
IoT-WorkS adds telemetry and traceability to batch, continuous and hybrid process plants across water, food and beverage, chemicals and pharma. Per-batch sensor records link raw materials, equipment runs and operator events, bridged from existing SCADA over OPC UA, MQTT and Modbus.
Where we deploy
3 typical use casesTank, vessel & pipeline telemetry
Level, pressure, flow and temperature sensors with hazardous-area certifications where the duty calls for it.
Batch genealogy + traceability
Per-batch sensor records linked to raw materials, equipment runs and operator events. Audit-ready, queryable, exportable.
SCADA + cloud bridges
OPC-UA, MQTT and Modbus bridges from existing SCADA systems into modern IoT dashboards - without replacing the controls layer.
What is batch genealogy and why does it matter?
It is the ability to reconstruct exactly what happened to one batch: which raw material lots went in, which equipment ran, what the process conditions were, and which operator actions occurred at each point. When a quality question arises, that record is the difference between recalling one batch and recalling a week's production. Continuous sensor logging makes it queryable rather than assembled from paper and separate systems.
- Raw material lots linked to the batches they entered
- Equipment runs, cleaning cycles and process conditions timestamped
- Operator events recorded against the batch rather than a shift log
- Queryable export for quality investigation and audit
Do we have to replace our SCADA system?
No. Existing SCADA keeps doing what it does well, which is supervisory control. We bridge over OPC UA, MQTT and Modbus to copy the data it already holds into a modern platform where history, analytics and cross-plant comparison are practical. Nothing in the control path changes, which is what keeps validation effort proportionate on a regulated site.
OPC UA standard (opcfoundation.org)How does this support food and pharma compliance?
By producing evidence continuously rather than at inspection. Temperature, pressure and hold-time records per batch are logged automatically with timestamps and equipment identity, so a deviation investigation has real data to work from. On food sites the same dataset supports hygiene and temperature-control obligations; on pharma sites it complements the validated systems already in place rather than replacing them.
Food Hygiene (England) Regulations 2006 (legislation.gov.uk)What does condition monitoring add on a process plant?
Warning. Pumps, agitators, compressors and CIP systems fail with signatures that appear days before the failure itself, and on a continuous plant an unplanned stop is expensive in ways a discrete factory does not experience - product in process is often lost with it. Vibration and current monitoring on critical rotating equipment typically gives 7 to 11 days of notice, enough to fold the repair into a planned shutdown.
Every vertical runs on the same engines: AI Telemetry for sensor data, Engineering services for hardware + firmware + integration, the same platform for dashboards, alerts and compliance exports. The vertical changes the asset class and the regulatory frame; the stack underneath doesn't.
Frequently asked questions
- Will you touch our control system?
- No. We bridge over OPC UA, MQTT and Modbus to read what SCADA already holds. Nothing in the control path changes, which keeps validation effort proportionate on a regulated site.
- What does per-batch traceability record?
- Raw material lots, equipment runs, process conditions and operator events, all timestamped against the batch, so a quality investigation can reconstruct one batch instead of quarantining a week of production.
- Can this run on a plant with older instrumentation?
- Yes. Where existing instruments expose Modbus or an analogue signal we read them, and where nothing exists we add wireless sensors, so older plant is instrumented without a full I/O upgrade.
- How much warning does condition monitoring give?
- Typically 7 to 11 days on critical rotating equipment such as pumps, agitators and compressors, which is enough to fold a repair into a planned shutdown rather than losing product to an unplanned stop.
- Is the data suitable for audit?
- Yes. Records are timestamped with equipment identity and exported on demand, which is what makes a deviation investigation evidence-based rather than reconstructed.
Tell us about your process automation project.
A local engineer will reply within one working day with a recommended sensor mix, gateway architecture and a rough deployment timeline.