Faith Technologies Inc.

Faith Technologies was operating an aging biodigester facility at a geographically remote site where legacy control infrastructure created compounding operational challenges. In the biogas sector, natural gas yield depends on precise management of biological processes — temperature, retention time, feedstock ratios — making real-time visibility essential, not optional. The facility's outdated systems provided no continuous data stream, leaving operators dependent on manual, retrospective reporting that obscured emerging process deviations. Without remote access, addressing issues at an isolated location required costly and time-consuming on-site intervention. The combination of poor process transparency, reactive maintenance posture, and an underdeveloped business model left the facility economically uncompetitive as a renewable energy asset.

Faith Technologies partnered with Rockwell Automation to modernize the facility's control and monitoring infrastructure across several integrated layers. At the process level, Rockwell's PlantPAx Distributed Control System replaced legacy controls, providing a unified automation backbone suited to the biological process demands of anaerobic digestion. PowerFlex 750-series variable frequency drives were deployed to optimize motor and pump operations, enabling precise flow regulation to maintain digester stability. On the visualization and data layer, FactoryTalk View SE delivered plant-floor HMI capability, while FactoryTalk ViewPoint extended operator access remotely — a critical capability for an isolated facility. FactoryTalk Historian captured continuous process data into a structured time-series database, converting raw sensor readings into reportable production records. Together, the stack established a connected, auditable operational environment from the field edge to the back office.

The modernization program delivered measurable improvements across both throughput and reliability. Daily natural gas output increased as tighter process control enabled more consistent biological performance within the digester. Monthly downtime decreased, with continuous condition data allowing operators to identify and address process deviations before they escalated into unplanned outages. Key outcomes include:

• Higher daily gas yield through stable drive performance and closed-loop process control
• Lower monthly downtime enabled by real-time monitoring and faster fault response
• Remote operational capability established for an isolated site, reducing dependence on costly on-site visits
• Audit-ready production reporting now supports carbon intensity tracking and renewable energy compliance requirements

• Legacy biodigester control systems are frequently the primary constraint on gas yield — upgrading the automation layer often unlocks latent capacity without requiring process redesign
• Remote access infrastructure is a prerequisite for economic viability at geographically isolated energy facilities, not an optional enhancement
• Pairing a process historian with a DCS creates the data foundation needed for renewable energy regulatory compliance and carbon intensity reporting
• VFD integration at the drive level stabilizes biological activity by enabling precise flow control, reducing both process variance and mechanical wear
• Integrated platform approaches reduce long-term vendor complexity and simplify maintenance at remote sites where support resources are limited