Challenge

Alltech's Bioplex process — slurry, drying, and packing — ran on Rockwell FTV SCADA and a Rockwell PLC, but needed batch reports, machine running status, and energy analysis dashboards, plus a way to record parameters like Moisture, Solid, Density, and pH that aren't captured automatically.

Outcome

Itanta's web application now logs 192 tags across 10 data source collections over Ethernet/IP and Modbus TCP, delivering slurry and drying batch reports with manual entry, a machine running status dashboard for all three Bioplex machines, and an energy analysis dashboard with daily consumption calculated in Formula Builder.

At a glance

• 192 — Tags Used
• 10 — Data Source Collections
• 3 — Bioplex Machines Monitored

About Alltech Biotechnology Pvt. Ltd.

Alltech Biotechnology Pvt. Ltd. runs a Bioplex production process spanning slurry, drying, and packing, controlled by a Rockwell PLC with FactoryTalk View SCADA.

Industry: Biotechnology / Animal Nutrition Manufacturing

Introduction

Alltech Biotechnology Pvt. Ltd. needed analytical dashboards and batch reports for its Bioplex process, built on top of its existing Rockwell FactoryTalk View (FTV) SCADA and Rockwell PLC infrastructure.

Itanta's web application collects data from the Rockwell PLC and an energy meter, stores it in Itanta's own database, and presents it as batch reports for the drying and slurry processes, a machine running status dashboard, an energy analysis dashboard, and a manual entry form for parameters that cannot be captured automatically — all accessible through a standard web browser for managers, engineers, supervisors, and operators.

Highlights

• 192 tags across 10 data source collections on a 256-tag license
• Batch data logging over Ethernet/IP from the Rockwell PLC
• Energy meter connected over Modbus TCP, logged every 1 minute
• Drying batch parameters logged every 5 minutes from batch start to end
• Manual entry form for slurry parameters not captured automatically
• Role-based users: full dashboard access and operator-only manual entry

Project Scope & Data Sources

What Itanta was configured to collect at Alltech

The project covers three logging patterns — batch data logging over Ethernet/IP, cyclic data logging over Ethernet/IP with namespaces, and cyclic data logging over Modbus TCP — feeding five user interfaces: the Drying Batch Report, Slurry Batch Report, Manual Entry form for slurry manual data, Energy Analysis Dashboard, and Machine Running Status Dashboard.

• 192 tags used out of a 256-tag license, organized into 10 data source collections
• Ethernet/IP Connector: batch and archive collections for the Bioplex Drying and Bioplex Slurry processes
• Ethernet/IP Connector with Namespace: raw drying duration, packing duration, and machine status data processed through namespace outputs
• Modbus TCP: a dedicated archive collection for the Energy Dashboard
• Every report carries Alltech's logo in the header with the report name, and page numbers in the footer

Project Architecture

Data Sources

The FBD (Fluid Bed Dryer) machine is controlled by a Rockwell PLC, and an energy meter (MFM386 - Select) measures the plant's electrical parameters.

• Itanta DS Manager reads from both devices — the Rockwell PLC over Ethernet/IP and the energy meter over Modbus TCP.

Connectors

The Itanta Ethernet IP Connector and Itanta Modbus Connector move data from the devices into the Itanta database.

• Ethernet/IP handles batch data logging for the Bioplex drying and slurry processes, plus cyclic data logging with namespaces for drying duration, packing duration, and machine status calculations.
• Modbus TCP handles cyclic logging of the energy meter parameters.

Processing & Analytics

Itanta Analytics and the Itanta Formula Builder work on the stored data.

• Namespaces derive each machine's running status from PLC start-command signals, and On-Change formulas calculate running durations.
• Formula Builder calculates daily energy consumption from the meter's absolute energy reading.

Dashboards & Reports

Itanta dashboards and reports present the results: the Drying Batch Report, Slurry Batch Report, Manual Entry form, Machine Running Status Dashboard, and Energy Analysis Dashboard.

• The Itanta Analytics Platform runs alongside FTV SCADA on the same industrial PC.

What Itanta Delivered

• Slurry Batch Report with Manual Entry: Selecting a batch number shows the slurry process data for that batch — start time, end time, serial number, and process parameters. Moisture, Solid, Density, and pH are not captured automatically, so a manual entry form lets operators record them after batch completion; saved values appear in the same report, with serial numbers kept unique per batch per day.
• Drying Batch Report: A batch-wise report showing Batch Number, Start & End Date/Time, Operator Name, and Total Batch Time, along with drying parameters such as FD Heating, FD Cooling, Pug Mixer, Seed Frequency, Beltweigher Weight, Liquid Flow Rate, Feed Pump Frequency, FBD Inlet/Outlet Temperature, Moisture PGM, Moisture FBD, Seed Silo Weight, Batch Density, and Liquid Level — logged every 5 minutes from batch start to end.
• Machine Running Status Dashboard: Running status for the Bioplex Slurry, Drying, and Packing machines is derived from PLC start-command logic via namespaces, with On-Change formulas calculating running duration. The dashboard shows current Running/Stopped status, running minutes versus total duration for the selected day, a status trend graph, and a donut chart per machine.
• Energy Analysis Dashboard: Energy meter data arrives over Modbus TCP and is logged every minute: average voltage LN/LL, average current, power factor, net and absolute energy readings, and phase-wise voltage and current. Daily energy consumption is calculated in Formula Builder from the absolute energy reading, with energy, voltage, and current trends on the dashboard.
• User Management: Two users were configured: a plant user with permission for all Alltech dashboards, and an operator user restricted to the Manual Entry dashboard only.

Snapshots of Dashboards & Reports

• Slurry Batch Report: Batch-wise slurry process data including start/end times, serial number, moisture, solid, pH, density, water used, and operator name.
• Drying Batch Report: Complete drying process record for a selected batch, logged every 5 minutes with heating, cooling, temperatures, weights, and moisture parameters.
• Machine Running Status Dashboard: Running/Stopped status, running duration, status trend, and donut visualization for the Bioplex Slurry, Drying, and Packing machines.
• Energy Analysis Dashboard: Live energy parameters, phase-wise voltage and current, and energy, voltage, and current trends from the Modbus-connected energy meter.

Conclusion

With Itanta running alongside Rockwell FTV SCADA on the same industrial PC, Alltech gets structured batch records for its slurry and drying processes, a clear machine-wise view of running performance, and continuous energy monitoring — with manual-entry provisions where automatic capture isn't possible, and role-based access so operators see exactly what they need.

Ready to Transform Your Manufacturing Data?

Alltech's Bioplex plant shows how Itanta layers batch reporting, machine status, and energy analysis on top of existing Rockwell infrastructure — without replacing anything. Your plant can do the same.