Client Overview
A group of small and medium textile SMEs dealing in weaving, dyeing, and finishing were dealing with outdated equipment, unreliable production records, and little expertise in automation. Being so small with less than 100 employees, the companies did not have the funds to update their machines or set up their own robotics teams.
What they needed was a solution that would make their work digital, lower the chance of errors and offer immediate insights into their operations without causing any interruptions or overspending.
About the Company
Key Challenges
Legacy Equipment Compatibility
The vast majority of HVAC machines were old analog ones, and they could not be used with recent automation tools.
Manual Processing
Operators could not see the big picture since they relied only on paper methods, which led to issues in their decisions.
Not enough Technical Staff
Having no automation experts at home, the company turned to other sources for assistance with regular problems.
Limited Capital for Upgrades
Replacing all the equipment and moving to automated systems was not financially possible.
Our Automation Solutions
Sensor Integration
New sensors for pressure, temperature, vibration, and speed were added to looms, dyeing machines, and boilers, helping collect important data without changing the main equipment.
Personalized PLC Programming
Set up ways to manage the older machines and use automation for dyeing and running the motors at the right moments.
User-Friendly Displays
Now, the operator can review fabric tension, the machine’s temperature, and its status through the displays, making it possible to avoid mistakes while working.
Safety & Compliance Upgrades
We made sure to put in place emergency safeguards, alerts, and alignment with regulations so that this would not disrupt employees’ work routines.
Ongoing Support
Functions such as remote troubleshooting, easy software updates and expert call support mean you don’t have to hire your own automation staff.
Tech Stack
IoT Devices : eInnosys Plug-and-Play Sensors, Allen-Bradley MicroLogix PLC
Cloud Platforms : Google Cloud IoT Core, Firebase
Dashboards : Custom Visual Interfaces, Grafana
Security : VPN Access, Multi-Factor Authentication
Measurable Impact
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