Case Study Highlights: Automation Wins Across Industries

  • 3 min read

At Opus Integration, we believe that great automation is more than technology—it’s the measurable improvement it brings to real operations across diverse industries. Our case studies showcase how strategic engineering, tailored control systems, and innovative integration help customers overcome challenges like obsolete systems, safety concerns, and rapid growth demands. From packaging modernization to distillery campus-wide automation, here are some recent success stories that illustrate how automation delivers tangible value.

Modernizing Packaging Machinery

In Indianapolis, a packaging manufacturer faced repeated downtime and safety concerns due to an antiquated control system built around obsolete stepper motor configurations. Opus Integration partnered with Innovative Production Technologies to redesign and rebuild the control architecture, integrating modern motion and safety capabilities. The new system features a GuardLogix 5380 controller, PanelView Plus HMI, Kinetix 5500 servo drives, and safety-enabled PowerFlex VFDs, delivering enhanced diagnostics, reliability, and operator usability.

The result was a significant reduction in downtime events and improved safety and troubleshooting capabilities—turning a previously problematic machine into a reliable contributor on the production line.

ElectroGuard Safety Modernization

Legacy hardwired safety circuits can be difficult to troubleshoot and maintain. That’s exactly the issue one large consumer products installation experienced with multiple ElectroGuard systems. Obsolescence and long maintenance cycles were causing extended downtime, affecting productivity. Opus Integration worked with ROSS Controls and Kimberly-Clark to migrate these systems to a programmable safety controller–based solution.

This modernization effort improved system availability and simplified diagnostics by providing backward compatibility with existing installations and enhanced operator interface feedback. The upgrade brought both performance and maintainability improvements to the safety subsystem—proving that even safety mechanisms can benefit from automation design evolution.

Greenfield Distillery Automation

Distilled spirits producers often face the challenge of blending traditional craft with modern manufacturing demands. Opus Integration recently completed a Greenfield Distillery Project in Bardstown, KY, deploying a sophisticated PlantPAx-based control system across multiple buildings. The solution integrates dozens of Allen-Bradley controllers, segmented Ethernet/IP networks with CIP Security, virtualized server infrastructure, and FactoryTalk visualization and historian platforms for enterprise-level data access.

This project brought real-time data visibility, secure communications, and scalable control to a facility that prioritized both quality and growth. By architecting the system with redundancy and future-proof design principles, Opus ensured that the distillery could expand without compromising performance.

Campus-Wide Distillery Expansion

Another standout example comes from a comprehensive automation deployment involving a multi-building campus. This system unified operations under a cohesive PlantPAx ecosystem, integrating multiple ControlLogix processors, redundant networking infrastructure, virtualized server clusters, and extensive operator workstations.

The solution delivered secure, scalable automation with optimized data flow and operational continuity, even through construction and phased commissioning. This type of large-scale rollout demonstrates Opus’s ability to manage complex, mission-critical automation projects with precision and minimal disruption.

Why These Wins Matter

Across industries—from consumer products and packaging to distilled spirits production—Opus Integration’s case studies show a consistent theme: smarter automation solves real problems. Whether it’s eliminating obsolete hardware, enhancing machine safety, or scaling complex plant systems, our approach combines engineering excellence with an eye toward long-term value.

If you’re facing challenges with aging systems, production bottlenecks, or safety concerns, these success stories illustrate what’s possible. Contact Opus Integration to explore how we can apply similar solutions to your operations.