Connected Enterprise

The Ukrainian sinter plant operated by Connected Enterprise faced a critical modernization challenge: its ageing control infrastructure was no longer capable of supporting data-driven process improvements that have become standard in competitive industrial machinery operations. Sintering is an energy-intensive process where real-time process visibility and precise control directly affect product quality, throughput, and energy consumption. Without modern automation, the plant lacked centralized monitoring, reliable data capture, and the remote access capabilities needed to respond to process deviations quickly. This gap left significant efficiency and energy savings on the table, while increasing operational risk from outdated, difficult-to-maintain legacy systems.

Connected Enterprise, working with Rockwell Automation, replaced the plant's legacy control infrastructure with a fully integrated modern automation architecture. At the core is an Allen-Bradley ControlLogix L83 programmable automation controller, providing the processing power needed for complex sintering process logic. Network connectivity was modernized through Industrial Ethernet switches configured with multiple EtherNet/IP-based Device Level Rings (DLR), delivering redundant, fault-tolerant communications across the plant floor. FactoryTalk View Site Edition SCADA, along with FactoryTalk View Server and Studio, was deployed to give operators a unified real-time process visualization and control environment. A brand new central control room was built to consolidate operations, and remote access capabilities were integrated to enable off-site monitoring and diagnostics.

The project delivered a fully modernized, connected automation environment across the sinter plant. Key outcomes include:

• Centralized control room: A new central control room replaced fragmented, localized operator stations, improving coordination and situational awareness.
• Automated asset management: FactoryTalk tools enabled automated tracking and management of automation assets, reducing manual maintenance overhead.
• Enhanced data capture: The new infrastructure dramatically increased process data fidelity, giving engineers the historical and real-time data needed to analyze and optimize sintering parameters.
• Improved energy control: Structured data collection and modern controls provided the foundation for better energy monitoring and consumption management across the energy-intensive sintering process.
• Remote access: Operators and engineers can now monitor and interact with plant systems remotely, improving response times and reducing downtime.

• Legacy sintering operations often lack the data infrastructure needed for optimization — modernizing the control layer is a prerequisite, not an optional upgrade.
• EtherNet/IP Device Level Rings provide network redundancy critical for continuous industrial processes where unplanned downtime is costly.
• A centralized SCADA deployment (FactoryTalk View SE) consolidates visibility across disparate plant areas and is a practical first step toward data-driven process improvement.
• Remote access capabilities should be built into the automation architecture from the outset, not retrofitted later.
• Engaging a systems integrator partner alongside the technology vendor (as Connected Enterprise did with Rockwell Automation) accelerates deployment and reduces integration risk.