All Equipment And Recipes Across 10 Lines Monitored With Single Project

Barry-Wehmiller Design Group — 2023 Finalist

6 min video  /  2 minute read

Project Summary:

This Ignition project came as a result of a controls-focused project on increasing OEE across 10 packaging lines, specifically monitoring two aspects of production. The first was trending the speeds of each piece of equipment on the line to allow users to monitor the V-Curve over time. The second was maintaining equipment recipe data and tracking when changes were made.



The first issue to address was monitoring equipment speeds, and ensuring the V-Curve of the line was being effectively controlled by the supervisory PLC as line backup and accumulation levels were changing. The line supervisory PLC had been accessed by many controls engineers over the years since installation, and therefore logic was inconsistently applied across the plant; sometimes without regard for effective packaging engineering principles.

As equipment centers were being improved with updates to their configuration, it was identified that operators were actively modifying equipment setpoints that had a direct effect on the overall speed of the equipment. Accumulation levels were occasionally decreased, or cycle rates slowed below the OEM recommendations, as the operators felt the equipment was “running too fast.”



The system needed to monitor tags, store tag history and user data to the database, and visualize the project natively on desktop and mobile devices. Additionally, because it was not scoped within the budget of the original project, this project’s rapid development time with quick wins was used to show results to stakeholders, allowing Barry-Wehmiller Design Group to get funding quickly and continue providing value to both the E. & J. Gallo Winery and the controls team making OEE improvements.



Because this project was initially built as a direct result of the controls team’s need to visualize data, it was not clear if there would be any adoption by E. & J. After the first line logged the speed trend, and the first equipment setpoint changes started being recorded, Design Group had the immediate attention of E. & J.’s management. Although the project was in a very early Alpha phase, the management team was already eagerly logging into the system many times a day to monitor the data being presented. The project has continued to be developed with the input from the E. & J.’s management and operations teams.


Deploy Date: August 2022

Project Scope:

Tags: 6,500

Screens: 5

Clients: 10-20

Alarms: 0

Devices used: iPad, iPhone, PC

Architectures used: IIoT architecture with additional Scale-Out servers

Databases used: 1 - Postgres

Historical data logged: 500 Tag History, Scripted monitoring ~6,000 tags for changes, and recording

Project Information

Created By:   Barry-Wehmiller Design Group

Barry-Wehmiller Design Group is a $350 MM company, with ~40 offices in the US with over 1,400 engineers, project managers, and other technical specialists, providing a broad range of services, including packaging automation, process engineering, facility design services, utility system engineering, software engineering, compliance and quality services, construction management, and design/fabrication of electrical control systems. Design Group serves a broad range of industries and market sectors including beverage, dairy, food, household and personal care, life sciences, chemical industry, energy, and utilities. With uncompromising respect to quality, confidentiality, and safety, Design Group focuses on developing long-term client relationships through proven execution.


Project For:   E. & J. Gallo Winery

E. & J. Gallo Winery is a privately owned wine and spirits company headquartered in California, USA. They produce and distribute a wide range of wines and other alcoholic beverages, including brandy, tequila, and vodka. With over 100 different brands, E. & J. Gallo Winery is one of the largest wineries in the world and operates in more than 110 countries. They are known for their innovative marketing strategies and commitment to sustainability in their production processes.


Posted on October 23, 2023