Transforming a Multi-Building Campus with PlantPAx: A Scalable, Secure, and Future-Ready Automation Solution
At Opus Integration, we believe that great automation is more than just technology—it’s about delivering intelligent, resilient, and scalable systems that empower our clients to operate with confidence and efficiency. Our recent PlantPAx deployment across a multi-building campus exemplifies this philosophy, combining deep technical expertise with a forward-thinking approach to industrial automation
Project Overview:
Our client had already seen the value of our work through several smaller-scale PlantPAx projects. These earlier successes laid the groundwork for a much larger and more complex initiative: a full-scale, campus-wide automation system that would unify operations, enhance visibility, and ensure long-term reliability.
With a proven track record of meeting expectations and delivering on time, we were selected to lead the design and implementation of this ambitious project.
At-A-Glance:
| Industry: | Distilled Spirits |
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The Client's Challenge
The client emphasized the need for continued operation during the 2 years of construction with two schedule process interruptions into a seamless commissioning.
Project Scope: A Campus-Wide Automation Ecosystem
The project encompassed:
12 Allen-Bradley ControlLogix Processors distributed across multiple buildings
7 IntelliCENTER MCCs equipped with PowerFlex 755 and 525 drives
Diverse I/O Platforms: 1734 for general environments and 1719 for hazardous areas
24 Operator Workstations and 2 Engineering Workstations
8 Dell R750 Servers running VMware for virtualization and redundancy
High-speed, redundant fiber network using Cisco Catalyst 9500 and 9200 switches
This was not just a control system—it was a fully integrated, secure, and virtualized automation platform designed to support both current operations and future growth.
The Opus Solution
Engineering Excellence in Action
- Intelligent Control Architecture
Twelve Allen-Bradley ControlLogix processors managed key processes across the campus, linked via a segmented network for secure, efficient communication. - Motor Control & I/O
Seven IntelliCENTER MCCs with PowerFlex 755 and 525 drives handled motor control.
- 1734 POINT I/O for non-hazardous areas
- 1719 Ex I/O for classified zones
This dual setup met both performance and safety needs.
- Secure, Scalable Networking
ControlLogix Ethernet/IP modules with CIP Security ensured encrypted communications.
A redundant star topology using Cisco Catalyst 9500/9200 switches over fiber enabled high availability and rapid failover. - Virtualization & Redundancy
Eight Dell R750 servers with VMware supported:
- Automatic failover
- Scalable VM deployment
- Centralized management
- All VMs used PlantPAx Virtual Templates for consistency and reliability.
- Integrated Software Suite
- FactoryTalk View SE for SCADA
- Historian SE for data analysis
- AssetCentre for version control
- ThinManager for secure thin client management
From Design to Deployment
We executed detailed design, FAT, on-site commissioning, and operator training—working closely with the client to ensure successful implementation.
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