Case Studies

OPC technology is currently installed in over 17 million machines and factories around the world. These case studies span several industries and highlight the real-world savings and benefits from using OPC technology.

Note: The views expressed in these documents do not necessarily reflect the views of the OPC Foundation.

Food production
OPC UA in world of food production

The Swiss machinery manufacturer Bühler plays a crucial role in meeting the basic food and mobility needs of two billion people. This is because a large proportion of the machines used in food production and die casting
come from Bühler. OPC UA is used since 2014 and it’s the base of their components “Pluto” and “Mercury MES”. Major industrial customers have increased the efficiency of their production and reduced energy waste and water consumption with Bühler’s OPC UA-based

Read about the impact of OPC UA and the case study here

SOLAR Energy
OPC UA in world largest solar park

The Norwegian systems integrator Prediktor is a leading provider of asset management and real-time data management solutions to renewable- and energy asset owners. It is also a global technology leader in OPC and OPC
UA. Mapping work- and production-flows with a view to automating management and control has been Prediktor’s focus from the company’s foundation in 1995. Learn about OPC UA in super large power plants like Benban Solar Park in Egypt by company Scatec.

Read about the impact of OPC UA and the case study here

Mechanical Engineering

Rosendahl Nextrom develops and manufactures equipment for the global cable, fiber optics and battery industry. The company is part of the KNILL GROUP, an Austrian group focused on industrial manufacturing. It supplies production technologies for battery machines (BM-Rosendahl), machines for the production of cable, wire and shocktubes (Rosendahl), as well as fiber optics
and fiber optic cables (Nextrom). Numerous products in the brands’ portfolio demonstrate global market leadership. Depending on the area, the company covers between 25 and 60 percent of the market. With automation solutions from Siemens and the OPC UA communication standard, Rosendahl Nextrom flexibly connects all production steps. Orders for cable or battery machine production can be implemented more efficiently and complex operating data can be collected  imultaneously.

Read about the impact of OPC UA and the case study here

Factory Automation

Miele is the world’s leading supplier of premium domestic appliances. These include the product segments cooking, baking, steam cooking, refrigeration and freezing, coffee preparation, dishwashing, laundry and floorcare. In addition, there are dishwashers, washing machines and tumble dryers for commercial use, as well as cleaning, disinfection and sterilization equipment for medical facilities and  Laboratories.
In May 2017, the first working group began operations
with the objective of reviewing the OPC UA standard. In 2018, Miele decided to rely on OPC UA in the press shop and body shop for the production of washing machines. Since 2018, the utilization of OPC UA for production communication has continuously increased in the BU Laundry. Today, OPC UA standards are also implemented when existing plants are remodeled, wherever possible. New plants are already equipped with OPC UA at the factory.

Read about the impact of OPC UA and the case study here

Cloud / Modelling
Process Industry
Strategies for data-driven digital transformation in the plant

Equinor is a broad energy company of 21,000 colleagues committed to turning natural resources into energy in more than 30 countries worldwide. As the largest operator in Norway and international  leader in offshore operations and renewable energy, Equinor is shaping the future of energy.
Digitalization is transforming the way Equinor works to support their strategies and goals, which are to use data to improve safety; reduce development and operating costs; increase recovery and discovery; and reduce greenhouse emissions.
Read about the impact of OPC UA and the case study here

Cloud / Modelling
Factory Automation
Digital Transformation at Groupe Renault

Groupe Renault’s plan is to implement the use of OPC UA-enabled devices and equipment at all production sites worldwide, and to implement end-to-end data communication from the
sensor to the machines to the cloud and back again using the OPC UA communication standard. Today, OPC UA is already being used in 17 of the 38 production sites with a total of 3,300 OPC UA-enabled devices.
Read about the impact of OPC UA and the case study here

Transportation Standardized Communication Structures in Detection Systems of Deutsche Bahn

The system DBMAS (DB-Meldeanlagensystem) is a new standardized solution for remotely controlling and monitoring alarm systems and further operationally relevant infrastructural facilities which has been called for tenders by DB AG in 2009. Facilities to be connected include amongst others hot box detection systems in the track area, wind sensor systems on bridges and dams, and safety devices of railway tunnels.
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Automotive Seamless Data Exchange via OPC-UA. Implementation of Product Control in a World-wide Network of Plants

With the industry-wide trend towards horizontal and vertical integration, intelligence is moving from the supervisory control systems to the local components. This development is leading to a growing need for communication for which the open OPC-UA standard provides an ideal solution because it can also be used for embedded devices. Softing’s embedded OPC-UA server gateway echocollect UA links the control world with the IT world and provides access to process, manufacturing and quality data in more than 50 different controller types.
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Company(SAFCO), a division of Saudi Arabia Basic Industries Corporation’s (SABIC), produces, processes, manufactures, and markets the principal fertilizers found in local and international markets.
In August of 2012, a number of heavy industry locations in the Middle East suffered a serious cyber attack. As a result, many of the companies in the region disconnected their manufacturing and process plant networks from their corporate networks.
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Energy Monitoring Embedded PC as a distributed data logger with OPC UA connection to the cloud

For optimal energy management of municipal buildings, it is necessary to be as informed as possible via rapid-response energy monitoring systems to report consumption of water, electricity and heat. The region around the city of Aachen, Germany, together with their premises management and the IT service provider regio iT has therefore introduced e2watch, which is based on advanced data logging technology from Beckhoff.
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Food and Beverage OPC UA middleware enables highly flexible food production – Weber integrates OPC UA into Slicing Machines

Weber Maschinenbau GmbH produces groundbreaking systems to process, refine and slice sausages, meat, cheese and other food: Slicer, Food Robotics, and Skinner. Weber is world market leader in the field of Slicer technology, Its customers are amongst others large meat companies, dairy factories and system catering businesses.
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Oil & Gas The Texas reputation for size comes with some mighty metrics to back it up. As the largest oil producer in the Union, the state’s wellheads are spread over 268,000 square miles. If you are in the oil and gas industry, on-site management and monitoring of land-based wells can be a logistical challenge as well as a considerable expense. The state boasts nearly one working oil or gas well for every square mile, each requiring stringent monitoring and reporting by the Railroad Commission of Texas, the governmental regulatory agency that oversees the state’s oil and gas industry.
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Oil & Gas Neste Jacobs is the Nordic region’s leading provider of technology, engineering and project services for the oil and gas, biorefining, petrochemicals and chemicals industries, including also the utilities and life science sectors. Prosys OPC Services has worked with Neste Jacobs to add the new OPC UA communication protocol to Advanced Process Control system and real-time process database (Case 1). Prosys has also provided an extension to Neste Jacobs’ NAPCON® Simulator – a training simulator system with hard control and alarm switches. Integration of the switches was based on OPC UA, which guarantees reliable communication and easy connectivity, as well as supports future expansions of the systems (Case 2).
Read Case 1…
Read Case 2…
Oil & Gas Exchanging your control systems data outside of your network securely is possible!

The need to share process data between production sites, refinery, petrochemical, gas and utility plants has been increasing for the past decade.These plants and production sites are typically located in the same area and have the need to exchange feed stocks, naphtha, ethane and utilities streams such as hydrogen, electricity, water, steam, and fuel gas, which created the requirement to exchange data between their metering and control systems.
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Water Treatment Intelligent Water Management with OPC UA Enabled Smart Devices

M2M Communication Based on PLCopen OPC UA Client Function Blocks

Decentralized, independently acting embedded controllers can form an intelligent network for the control of potable water and waste water plants. OPC UA is the ideal technology to establish secure and standardized M2M interaction at these plants.
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To submit a case study for publication on the OPC Foundation web site, please review the requirements for contributed content.