Challenge

Sangam Dairy's advanced milk processing facility ran on disconnected Rockwell PLCs, flowmeters, weighbridges, and manual paper records—creating data silos, time-consuming manual workflows, and no real-time visibility across parallel processing lines.

Outcome

Working with system integrator CRK, Itanta Analytics delivered a comprehensive Industrial IoT web application that unified PLC and manual data, automated batch logging, enabled digital quality gates, and provided real-time visibility from weighbridge to dispatch.

At a glance

• 30-Sec — Automated Batch Logging
• 3 — Parallel Lines Monitored
• Real-Time — Quality Gates

About Sangam Dairy

Sangam Dairy (Sangam Milk Producer Company Limited) is one of South India's leading dairy cooperatives, operating an advanced milk processing facility serving farmers and consumers across Andhra Pradesh and Telangana. Its digital transformation was led by CRK, a leading system integrator, in partnership with Itanta Analytics.

Headquarters: Andhra Pradesh, India · Industry: Dairy / Food & Beverage · Size: Large Cooperative

Introduction

When CRK, a leading system integrator, sought to digitally transform their client Sangam Dairy's advanced milk processing facility, they partnered with Itanta Analytics to bridge the gap between industrial automation and actionable intelligence.

This case study reveals how Itanta delivered a comprehensive Industrial IoT web application that unified data points from Rockwell PLCs, automated manual workflows, and provided real-time visibility across weighbridge operations, pasteurization processes, quality labs, and predictive maintenance. Discover how the Itanta-CRK partnership turned operational complexity into competitive advantage—delivering enhanced efficiency, complete traceability, and data-driven decision-making for Sangam Dairy, one of South India's leading dairy cooperatives.

Pain Points in Dairy Operations

Before Itanta, Sangam Dairy's processing operations were held back by fragmented systems and manual workflows that could not scale with the plant's complexity.

• Disconnected Data Across Systems: Data from Rockwell ControlLogix PLCs, flowmeters, weighbridges, and sensors existed in isolated silos with no unified platform for aggregation or analysis.
• Time-Consuming Manual Processes: Operators spent hours manually recording weighbridge entries, lab quality parameters (FAT, SNF, COB, acidity), filling machine data, and lab utility checks—introducing inefficiency and errors.
• Complex Multi-Compartment Calculations: Managing production across different sections (Raw Milk Storage Tank, Pasteurized Milk Storage Tank, Cream lines) with multiple lines (B1L1, B1L2, E1L1, E1L2) and tracking batch statuses (Aborted/Completed/Ended) created operational complexity manual systems couldn't handle.
• No Real-Time Visibility: Running three parallel processing lines simultaneously without live monitoring, management couldn't track batch status, temperatures, or equipment performance across operations in real time.
• Poor End-to-End Traceability: Tracking each tanker from weighbridge through lab testing, processing across different lines, and final dispatch was fragmented across paper records, compromising quality control.
• Reactive Maintenance: No systematic tracking of valve stroke counts, motor running hours, or preset maintenance thresholds resulted in unexpected equipment failures and unplanned downtime across the facility.

Highlights

• Unified Rockwell ControlLogix PLC data into a single Industrial IoT platform
• Automated batch-type logging at 30-second intervals across processing sections
• Digital quality gates (FAT, SNF, COB) ensuring only Pass results proceed
• Real-time visibility across three parallel pasteurization circuits
• Bi-directional PLC writeback for complete tanker-to-dispatch traceability

The Itanta platform amplified Sangam Dairy's existing Rockwell ControlLogix infrastructure through intelligent Analytics Layer integration—without disrupting it.

Sangam Dairy

A Leading South Indian Dairy Cooperative

Sangam Dairy operates an advanced milk processing facility serving farmers and consumers across Andhra Pradesh and Telangana. Its operations span weighbridge intake, raw and pasteurized milk storage, cream lines, quality labs, and dispatch—powered by Rockwell ControlLogix automation.

• Processes milk across Raw Milk Storage Tank, Pasteurized Milk Storage Tank, and Cream line sections
• Runs multiple production lines including B1L1, B1L2, E1L1, and E1L2
• Operates three parallel processing circuits: CIP, milk pasteurization, and cream pasteurization
• Relies on Rockwell ControlLogix PLCs, flowmeters, weighbridges, and quality lab instrumentation
• Manages end-to-end traceability from tanker intake at the weighbridge through dispatch
• Partnered with system integrator CRK to drive its digital transformation with Itanta Analytics

By unifying automation and manual workflows, Sangam Dairy laid the foundation for a fully digital, traceable, and data-driven dairy operation.

System Architecture

Data Collection Layer

Multiple data sources across the facility feed real-time information into the platform.

• PLC Systems — several tags from Rockwell ControlLogix covering Labs, Tanks, and different types of storage.
• Manual Forms — weighbridge operator entries for tanker details, driver information, and compartment data.

Integration Hub — Data Source Manager

Itanta's DS Manager orchestrates all data flows using the Ethernet IP Connector for PLC communication.

• Aggregates automated sensor data and manual entries into organized collections for unified processing.
• Connects directly to Rockwell ControlLogix PLCs via the Ethernet IP Connector.

Bi-Directional Communication

A critical writeback loop enables data entered at the weighbridge to flow back to the PLCs.

• Ensures downstream lab operations and processing logic have access to tanker information.
• Powers quality gates and production tracking with consistent, shared data.

Dashboard Visualization

The Itanta Platform delivers real-time web dashboards accessible via standard browsers.

• Displays process parameters, batch statuses, quality metrics, maintenance alerts, and production tracking.
• Provides simultaneous visibility across all processing lines from any browser.

How Itanta Transformed CRK Operations

From Disconnected Systems to Unified Intelligence

Itanta deployed a comprehensive Industrial IoT web application over Sangam Dairy's existing Rockwell ControlLogix infrastructure—unifying data, automating workflows, and digitizing quality and traceability across the plant.

• Unified Data Integration: Deployed the Ethernet IP Connector to integrate all tags from Rockwell ControlLogix PLCs into organized collections, creating a single source of truth.
• Intelligent Automated Logging: Implemented batch-type data logging with 30-second intervals—when running boolean bits turn true, data logs automatically until batch completion.
• Namespace Configuration: Deployed namespace monitoring for milk transfer lines, analog inputs, maintenance valves, and motors—pivoting time-sorted data into line-wise, equipment-wise actionable reports.
• Multi-Section Production & Quality Management: Created trigger-based logging across Raw Milk and Pasteurized Milk sections, custom forms with 'Get Value' buttons for real-time weights, and digital quality gates (FAT, SNF, COB) ensuring only 'Pass' results proceed.
• Centralized Real-Time Dashboard System: Delivered unified dashboards providing simultaneous visibility into three parallel processing lines—CIP, milk pasteurization, and cream pasteurization—accessible from any browser.
• Complete Traceability with PLC Writeback: Built integrated workflows using the Analytics Layer for bi-directional communication—weighbridge data automatically writes back to the PLC for downstream lab operations.

The result was a connected, automated, and traceable dairy operation—built on top of Sangam Dairy's trusted Rockwell ControlLogix infrastructure.

Data Visualization

Sangam Dairy's dashboards provide real-time visibility into cold storage conditions and lab quality testing across the facility.

• Cold Storage Inventory: Real-time temperature monitoring across Milk Cold Storage, Curd Cold Storage, Cold Blast Room, and Incubation Room sections—tracking each zone in Deg.C with time-stamped readings for full cold-chain assurance.
• Lab Testing Report: Compartment-wise quality results for each tanker—capturing FAT, CLR, SNF, acidity, COB, organoleptic, heat stability, and alcohol tests—with instant digital quality gates ensuring only passing milk proceeds to processing.

Before vs After

Itanta didn't just implement new software—it fundamentally changed how Sangam Dairy operates, turning disconnected systems and manual processes into a story of digital transformation.

• Unified — One Platform. Isolated data points became one unified platform accessible organization-wide
• 30-Sec — Automated Logging. Hours of manual paperwork replaced by automated batch logging every 30 seconds
• Predictive — Maintenance Alerts. Reacting to equipment failures gave way to predictive alerts for valves and motors
• 3 Lines — Synchronized Visibility. Fragmented triple-circuit operations became synchronized visibility across parallel lines
• Digital — Quality Workflows. Paper-based quality checks became digital workflows with PLC writeback integration

Conclusion

When Sangam Dairy, through CRK, used Itanta, they weren't just implementing new software—they were fundamentally changing how their dairy plant operates. What started as a challenge of disconnected systems and manual processes became a story of digital transformation that empowered their entire team.

• Operators trace every tanker from gate to dispatch using unique IDs
• Lab technicians trigger compartment-wise testing with instant quality gates
• Plant managers monitor three parallel pasteurization circuits simultaneously
• Maintenance teams receive alerts when valve strokes or motor hours approach preset thresholds
• A single unified platform replaced isolated data points across the facility
• Digital workflows with PLC writeback replaced paper-based quality checks

Inspired by what you've seen?

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