Digital Plant Automation

Digital Plant Automation for a Global Food & Beverage Manufacturer

About Customer

A global leader in the food and beverage industry, the customer is widely recognised for developing innovative flavours and fragrance solutions used across diverse consumer products. With growing production demands and increasing expectations around responsiveness, quality, and plant efficiency, the organisation set out to modernise its automation environment with a scalable digital infrastructure.

Business Requirement

The customer aimed to implement a robust and future-ready digital automation platform to support plant-wide operational excellence. The key requirements included:

Global implementation of a virtualised DCS-based automation platform

Remote monitoring and control for improved plant visibility

Energy and utility management for greater operational efficiency

Faster time to market while maintaining product quality

Improved scalability to support future expansion

Reduced downtime and improved plant productivity

The objective was not only to modernise the automation infrastructure but also to establish a connected, resilient, and scalable system capable of supporting continuous production, centralised monitoring, and faster decision-making.

Challenges

Before implementation, the customer faced several operational and system-level challenges common to large process manufacturing environments:

Legacy systems limited plant-wide visibility and centralised monitoring

Growing production demands required a more scalable automation architecture

Unplanned downtime impacted production continuity and delivery schedules

Limited integration between systems reduced real-time operational visibility

Business expansion required a standardised automation platform for future deployments

In a highly competitive food and beverage industry, the customer required a solution that could improve agility while maintaining process reliability and consistent product quality.

Softcon's Solution

Softcon designed and implemented an integrated DCS-based automation and virtualisation solution that delivered a highly available and scalable digital control environment. The solution included:

DCS-based control system with distributed I/O architecture

Plantwide Device Level Ring (DLR) Network

Redundant HMI, Alarm and Data servers

Historian Server with Redundant Interface Node

Redundant ThinManager Server with Unlimited Clients

VMware-based Virtualisation

Asset Management, Version Management and Disaster Recovery

The implemented architecture provided a secure, reliable, and future-ready automation platform capable of supporting both current production requirements and future plant expansion.

Solution Architecture Highlights

The digital automation architecture was designed to improve reliability, visibility, and operational continuity across the plant.

Key highlights included:

Virtualised automation environment for efficient infrastructure utilisation and simplified system management

Redundant server architecture to minimise operational interruptions

ThinManager-based centralised visualisation for secure and flexible operator access

Historian integration for process data collection, trend analysis, and process optimisation

Plantwide DLR network ensuring reliable communication across connected systems

Asset management, version control, and disaster recovery to strengthen business continuity

Implementation Approach

Softcon executed the project with minimal disruption while ensuring a smooth transition to the new digital platform.

Requirement Analysis & System Design
• Detailed assessment of plant operations, customer requirements, and future expansion plans.

Automation Platform Engineering
• Design and configuration of the DCS-based automation architecture and virtualisation environment.

Network & Redundancy Implementation
• Deployment of Plantwide DLR networking and redundant servers for critical applications.

Visualisation & Remote Operations
• Integration of ThinManager and HMI systems for centralised plant monitoring and control.

Data Integration & Historian Setup
• Configuration of historian systems for reliable process data collection, storage, and redundancy.

Testing, Validation & Commissioning
• Comprehensive testing to ensure system performance, reliability, and operational readiness.

Outcomes & Business Benefits

Faster Time to Market

A standardised automation platform enabled quicker production readiness and simplified implementation of operational changes.

Stronger Digital Infrastructure
Virtualisation, Plantwide DLR networking, and redundant servers created a highly reliable and secure automation environment.

Improved Product Quality
Enhanced process monitoring and better operational visibility improved process consistency and reduced process variations.

Better Plant Visibility
Centralised HMI, historian integration, and remote monitoring provided real-time operational insights across the plant..

Faster Decision-Making
Real-time access to alarms, trends, historical data, and operational status enabled quicker and more informed decisions

Reduced Downtime & Higher Productivity
Redundant system architecture and disaster recovery capabilities minimised downtime and improved overall plant productivity.

Business Impact Summary

Area Impact
Operations
Higher uptime, improved control, better plant visibility
Scalability
Ready for future expansion and multi-site deployment
Quality
Improved process consistency and reduced rejection risk
IT/OT Reliability
Redundant architecture with virtualised infrastructure
Decision Support
Real-time operational insights for faster decisions
Business Agility
Greater flexibility to support changing production demands

Why This Project Matters

For food and beverage manufacturers, operational continuity, product consistency, and production efficiency are essential for long-term success.

This project demonstrates how a modern DCS-based automation platform, combined with virtualisation, ThinManager, historian integration, and redundant system architecture, can transform traditional manufacturing into a connected, resilient, and future-ready operation.

The solution provides improved visibility, higher reliability, faster response times, and a scalable foundation for digital transformation.

Conclusion

Softcon successfully delivered a modern digital automation infrastructure that combines advanced process control, virtualisation, and operational reliability.

By implementing a scalable DCS-based automation platform with integrated visualisation, historian systems, ThinManager, and robust redundancy, the customer established a strong foundation for smarter manufacturing and future growth.

The result is a more connected, reliable, and efficient production environment that supports:

Improved operational continuity

Better plant visibility

Faster decision-making

Reduced downtime

Higher productivity

Scalable infrastructure for future expansion

Neeta Kulkarni

Head Projects

Neeta Kulkarni

HR and CSR Director, Softcon

Neeta Kulkarni is the dedicated HR and CSR Director at Softcon Systems Private Limited. With a strong passion for people and positive change, she plays a key role in building a supportive and inclusive work environment. Her efforts help employees grow, stay motivated, and feel valued.

As a leader in Corporate Social Responsibility (CSR), Neeta also ensures that Softcon contributes meaningfully to society. From community development to employee well-being, she focuses on making a lasting impact both inside and outside the organization.

Her leadership blends care, strategy, and social awareness, helping Softcon grow as a people-first and purpose-driven company.

Sales Director at Softcon - provides VFD/AC/DC Drive Repair Services in Pune,India,

Vinayak Hegde

Director Sales

Vinayak Hegde

Director Sales, Softcon

Vinayak is a seasoned professional with many years of experience in creating strategic roadmaps, driving corporate growth, and delivering impressive results. He has led high-performing teams and managed diverse responsibilities, significantly increasing annual revenues for multinational companies. His innovative approach has helped companies like Siemens and GE double their revenue in record time by breaking into competitive markets.

An expert in IIoT-connected enterprise solutions and product management, Vinayak is a true source of wisdom in automation, people management, and thoughtful leadership. His dedication to quality and continuous improvement consistently propels groundbreaking achievements across various industries, making him a key force in transforming business challenges into growth opportunities.

Service Head in softcon, Best AC/DC drive repairs services in india

Chintamani Unde

Service Head

Chintamani Unde

Service Head, Softcon

Chintamani Unde is a seasoned leader responsible for overseeing the entire maintenance and drives repair department, bringing extensive expertise and unwavering passion to his work.

With a strong background in managing large-scale service teams and optimizing repair processes, he consistently drives operational excellence and innovation. His strategic approach has reduced service downtime, improved customer satisfaction through proactive maintenance strategies, and optimized operational costs without compromising quality.

Chintamani’s commitment to translating vision into action and his ability to lead cross-functional teams ensure that the organization upholds high standards of quality and reliability, making him essential to boosting customer happiness and overall service performance.

Umesh Kulkarni - Project Director, Softcon is best Drive repair services company in pune ,india

Umesh Kurulkar

Project Director

Umesh Kurulkar

Project Director, Softcon

Umesh Kurulkar is the Project Director and the driving force behind our smooth operations. With many years of experience, he has built a team that works together efficiently to reach clear goals.

Umesh is known for his practical approach to solving problems and improving everyday work. He focuses on turning ideas into simple, clear actions that help the company grow and succeed. His strong leadership and dedication to continuous improvement have made the company a leader in the industry.

Umesh’s hands-on style ensures that every part of the business works well, creating a culture of steady progress and success.

Mansing Beloshe

Head Projects

Mansing Beloshe

Head Projects, Softcon

Mansing Beloshe is an experienced Project Manager with a strong background in the industrial automation industry. With expertise in Process Control, Engineering, Control Systems Design, Process Automation, and Project Engineering, he has successfully led numerous projects, driving efficiency and innovation.

His strategic approach to program and project management ensures seamless execution, from planning to implementation. A graduate of Sanjween Vidhyalay, Panchgani, Mansing is committed to delivering high-quality automation solutions that enhance operational performance and reliability.

Chintamani Unde

Service Head

As a Senior Manager for Service & Repair at Softcon Systems Pvt. Ltd., Chintamani Unde contributes knowledge and a commitment to providing outstanding service solutions.

Chintamani is essential to boosting customer happiness and upholding the organization's high standards of quality because of its emphasis on streamlining repair procedures and guaranteeing operational excellence.

Vinayak Hegde

Director Sales

Vinayak Hegde is a seasoned professional with 26 years of experience in creating strategic roadmaps, accelerating corporate growth, and producing significant outcomes. He has effectively led high-achieving teams, handled a variety of activities, and overseen yearly revenues of INR 60 crores. Vinayak has been instrumental in helping Siemens and GE double their revenue in record time by using creative tactics to break into cutthroat sectors.

He is an expert in IIoT, linked enterprise solutions, and product management, and he was awarded the Best Project Award at IIM Bengaluru. He also provides automation knowledge and thought leadership. Vinayak's dedication to quality keeps propelling revolutionary achievement in a variety of sectors.

Chandrakant Kulkarni

Managing Director

Chandrakant Kulkarni

Managing Director, Softcon

Chandrakant Kulkarni holds a degree in Electrical Engineering and Management, which laid the foundation for his technical and entrepreneurial journey. His early roles in small companies helped him develop expertise in operations, marketing, and technology, ultimately paving the way for him to establish his own company within a decade.

Initially specializing in power management and process automation, his venture expanded over 22 years into IoT, motion control, and end-to-end integration. His leadership is driven by a relentless passion for innovation and solving complex challenges, creating significant value for customers and stakeholders.

With a visionary approach, Chandrakant Kulkarni continues to inspire industry transformation, setting new benchmarks in technological advancements and business excellence.