{"id":2025,"date":"2026-06-02T13:10:18","date_gmt":"2026-06-02T11:10:18","guid":{"rendered":"http:\/\/proctec-staging.seiten.co\/referenzen\/case-study-rema-tip-top-ag-plc-sequence-control-with-s88-architecture\/"},"modified":"2026-06-16T10:48:53","modified_gmt":"2026-06-16T08:48:53","slug":"case-study-rema-tip-top-ag-plc-sequence-control-with-s88-architecture","status":"publish","type":"referenzen","link":"https:\/\/www.proctec.de\/en\/references\/case-study-rema-tip-top-ag-plc-sequence-control-with-s88-architecture\/","title":{"rendered":"Case Study \u201cREMA TIP TOP AG\u201d: PLC Sequence Control with S88 Architecture"},"content":{"rendered":"\n<h2 class=\"wp-block-heading\">Vom klassischen Leitsystem hin zu einer intelligenten, S88-basierten Produktionsarchitektur<\/h2>\n\n<p class=\"wp-block-paragraph\">As part of the expansion of a CP area at the Poing site,<\/p>\n\n<p class=\"wp-block-paragraph\">REMA TIP TOP AG faced the task of fundamentally upgrading its production architecture. <\/p>\n\n<p class=\"wp-block-paragraph\">The system was completely redesigned and implemented in close collaboration with plant manufacturers. <\/p>\n\n<p class=\"wp-block-paragraph\">Interfaces to third-party control systems were not an afterthought but an integral part of the system architecture from the very beginning.<\/p>\n\n<p class=\"wp-block-paragraph\">The central question was how to integrate a consistent, modern PLC sequence control system into a production environment that had previously been characterized by heterogeneous structures, separate data storage systems, and varying degrees of automation. <\/p>\n\n<p class=\"wp-block-paragraph\">The goal was to transform the existing architecture into an intelligent, S88-based overall structure.<\/p>\n\n<h2 class=\"wp-block-heading\">1. Initial Situation<\/h2>\n\n<p class=\"wp-block-paragraph\">The initial situation was characterized by a series of technical and structural challenges. <\/p>\n\n<p class=\"wp-block-paragraph\">In the existing environment, various systems operated with heterogeneous control structures. <\/p>\n\n<p class=\"wp-block-paragraph\">In some cases, integration between lines and systems was lacking. Production processes were not consistently mapped digitally, and data was distributed across PLCs, visualization systems, and databases.  <\/p>\n\n<p class=\"wp-block-paragraph\">As a result, there was no end-to-end PLC process control across the entire structure in this form.<\/p>\n\n<p class=\"wp-block-paragraph\">The key starting points were:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Diverse systems with heterogeneous control structures<\/li>\n\n\n\n<li>In some cases, there was a lack of integration between lines and systems<\/li>\n\n\n\n<li>Production processes were not consistently mapped digitally<\/li>\n\n\n\n<li>Data was scattered across PLCs, visualization systems, and databases<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\">Why proCflex?<\/h3>\n\n<p class=\"wp-block-paragraph\">oCflex was considered the appropriate foundation for the implementation. The standards are designed in accordance with European norms and CE conformity, and can be set up and operated in any country in accordance with these standards. <\/p>\n\n<p class=\"wp-block-paragraph\"><strong>Advantages:<\/strong><\/p>\n\n<ul class=\"wp-block-list\">\n<li>Automated and flexible processes in dosing and mixing plants can reduce staffing requirements at the facility.<\/li>\n\n\n\n<li>The solution is designed for MTP capability and thus supports modular integration approaches.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">Additionally, a structural limitation of existing batch systems became apparent. Common solutions such as SIMATIC Batch or InBatch primarily implement process control on a server-based architecture.  <\/p>\n\n<p class=\"wp-block-paragraph\">This led to increased system overhead, additional signal propagation times, and a heavy reliance on central instances. <\/p>\n\n<p class=\"wp-block-paragraph\">At the same time, PLCs and visualization previously had to be laboriously programmed manually, making the process time-consuming and error-prone. <\/p>\n\n<p class=\"wp-block-paragraph\">Against this backdrop, PLC process control came into focus as an alternative approach.<\/p>\n\n<p class=\"wp-block-paragraph\">The disadvantages of the existing conventional batch systems were particularly evident in the following areas:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Significant coordination effort between systems<\/li>\n\n\n\n<li>Limited transparency in the production process<\/li>\n\n\n\n<li>Potential for malfunctions and downtime<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">The central challenge was therefore to create a seamless, integrated control and data structure that overcomes existing system boundaries while simultaneously opening up new possibilities in batch automation. This is precisely where the subsequent PLC sequence control comes into play in the new architecture. <\/p>\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"473\" height=\"1024\" src=\"https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/rema-tip.top-Ausgangssituation-473x1024.jpg\" alt=\"Initial Situation Case Study: REMA TIP TOP AG\" class=\"wp-image-1457\" srcset=\"https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/rema-tip.top-Ausgangssituation-473x1024.jpg 473w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/rema-tip.top-Ausgangssituation-139x300.jpg 139w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/rema-tip.top-Ausgangssituation-768x1662.jpg 768w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/rema-tip.top-Ausgangssituation-710x1536.jpg 710w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/rema-tip.top-Ausgangssituation-946x2048.jpg 946w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/rema-tip.top-Ausgangssituation-scaled.jpg 1183w\" sizes=\"auto, (max-width: 473px) 100vw, 473px\" \/><\/figure>\n\n<h2 class=\"wp-block-heading\">2. Solution with Innovations<\/h2>\n\n<p class=\"wp-block-paragraph\">The complete loading of S88-compliant sequence controls directly into the PLC at the start of the job, combined with centralized deployment, opens up new possibilities. This approach to PLC sequence control combines the advantages of standardized batch control with execution shifted to the control level. <\/p>\n\n<p class=\"wp-block-paragraph\">This results in the following potential benefits:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>The solution supports flexible manufacturing instructions for varying production requirements.<\/li>\n\n\n\n<li>Lower latencies reduce response times within the system network.<\/li>\n\n\n\n<li>Reduced system dependency increases the stability of process execution.<\/li>\n\n\n\n<li>The approach lowers testing and engineering costs throughout the project.<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\">Architecture Changes and System Limits<\/h3>\n\n<p class=\"wp-block-paragraph\">The transition from server-based process control to a PLC-centric client architecture presented a major challenge. <\/p>\n\n<p class=\"wp-block-paragraph\">This required taking the PLC\u2019s limited resources into account while simultaneously minimizing the communication load between system components.<\/p>\n\n<figure class=\"wp-block-image size-full is-resized\"><img loading=\"lazy\" decoding=\"async\" width=\"409\" height=\"343\" src=\"https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/case-study-rema-tip-top-ag-e1780398112399.png\" alt=\"\" class=\"wp-image-1429\" style=\"aspect-ratio:1.1954753897890553;width:514px;height:auto\" srcset=\"https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/case-study-rema-tip-top-ag-e1780398112399.png 409w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/case-study-rema-tip-top-ag-e1780398112399-300x252.png 300w\" sizes=\"auto, (max-width: 409px) 100vw, 409px\" \/><\/figure>\n\n<p class=\"wp-block-paragraph\">In this context, the PLC-based process control represented not only a technical transition but also a fundamental architectural change.<\/p>\n\n<p class=\"wp-block-paragraph\">Another advantage is that the previously separate data stores in the database, visualization, and PLC can be consolidated into a unified deployment engine without:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>losing flexibility for different production specifications<\/li>\n\n\n\n<li>or violating the requirements of the ISA-88 (S88) standard<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">Furthermore, dependencies on third-party vendors and their system limitations are circumvented. <\/p>\n\n<p class=\"wp-block-paragraph\">The result was a high-performance, scalable, and standards-compliant solution that is flexible in its application, can integrate various systems, and simultaneously reduces engineering effort in the long term. The PLC sequence control is a central component of this solution. <\/p>\n\n<h2 class=\"wp-block-heading\">Objective<\/h2>\n\n<p class=\"wp-block-paragraph\">The goal of the project was to fundamentally modernize the new production facilities with discontinuous, batch-oriented manufacturing and transition them into a flexible, digitally controlled overall architecture. <\/p>\n\n<p class=\"wp-block-paragraph\">The initial situation was characterized by rigid manufacturing regulations, limited automation levels, and separate systems in the control, visualization, and supervisory levels.<\/p>\n\n<p class=\"wp-block-paragraph\">This fragmented structure led to high manual effort, limited flexibility, and an increased potential for errors during changes or new projects. <\/p>\n\n<p class=\"wp-block-paragraph\">To address these challenges, the goal was to consistently structure the systems in accordance with the ISA-88 (S88) standard. <\/p>\n\n<p class=\"wp-block-paragraph\">To this end, the processes were divided into units, phases, and transfers, laying the foundation for end-to-end automation. <\/p>\n\n<p class=\"wp-block-paragraph\">This structure was implemented consistently. For the PLC sequence control, this consistent structuring was an essential prerequisite. <\/p>\n\n<p class=\"wp-block-paragraph\">Of central importance was consistent and uniform naming across all involved levels:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>The naming conventions for valves, motors, sensors, and actuators were consistently coordinated with the systems engineer.<\/li>\n\n\n\n<li>A uniform naming convention was also consistently implemented in the electrical schematics.<\/li>\n\n\n\n<li>The proCflex control system uses the same consistent naming logic.<\/li>\n\n\n\n<li>The naming conventions were also standardized in the database, SCADA, and visualization systems.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">A central component of the project was also the introduction of a unified database in the MES system. <\/p>\n\n<p class=\"wp-block-paragraph\">Whereas control data (PLC), visualization content, and control system information were previously managed in separate systems, these were to be consolidated and centrally controlled in the proCflex MES going forward.<\/p>\n\n<p class=\"wp-block-paragraph\">Building on this, the goal was to automate engineering processes to a large extent. Using a \u201cDeploy-to-Clients\u201d logic, control and visualization structures were to be automatically generated and transferred to the respective systems. <\/p>\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"1280\" height=\"591\" src=\"https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/rema-tip-top-ag.jpeg\" alt=\"REMA TIP TOP AG\" class=\"wp-image-1452\" srcset=\"https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/rema-tip-top-ag.jpeg 1280w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/rema-tip-top-ag-300x139.jpeg 300w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/rema-tip-top-ag-1024x473.jpeg 1024w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/rema-tip-top-ag-768x355.jpeg 768w\" sizes=\"auto, (max-width: 1280px) 100vw, 1280px\" \/><\/figure>\n\n<p class=\"wp-block-paragraph\">This was intended to ensure that the PLC sequence control was not only implemented with technical consistency but also rolled out efficiently.<\/p>\n\n<p class=\"wp-block-paragraph\">The result:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>The system can be operated fully automatically in \u201cAutomatic\u201d mode.<\/li>\n\n\n\n<li>Manual interventions are significantly reduced during operation.<\/li>\n\n\n\n<li>At the same time, the solution increases flexibility in terms of recipes and processes.<\/li>\n\n\n\n<li>For new projects, engineering effort can be reduced by up to two-thirds.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">The project thus specifically bridges the gap between traditional, static batch production and a modern, scalable, and digitally integrated manufacturing environment with PLC sequence control.<\/p>\n\n<h2 class=\"wp-block-heading\">3. The Solution: S88-based automation architecture with the new proCflex<\/h2>\n\n<p class=\"wp-block-paragraph\">To implement this, the existing concept was expanded to include an innovative system architecture. At its core, this solution combines a central control system, an S88-compliant structure, direct PLC sequence control, central deployment logic, and end-to-end visualization and line integration. <\/p>\n\n<h3 class=\"wp-block-heading\">1. Central Control System (proCflex)<\/h3>\n\n<p class=\"wp-block-paragraph\">The control system handles the complete coordination of production. This includes: <\/p>\n\n<ul class=\"wp-block-list\">\n<li>Material, recipe, and order management<\/li>\n\n\n\n<li>Order control<\/li>\n\n\n\n<li>Automatic weighing and dosing<\/li>\n\n\n\n<li>Process data acquisition and batch records<\/li>\n\n\n\n<li>Integration with the ERP system (Oxaion)<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">The result is a central database within the MES instead of distributed systems. This creates the foundation for consistent process control and for integrating the PLC sequence control into a unified data structure. <\/p>\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"1280\" height=\"591\" src=\"https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/zentrales-Leitsystem-proCflex.jpeg\" alt=\"\" class=\"wp-image-1455\" srcset=\"https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/zentrales-Leitsystem-proCflex.jpeg 1280w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/zentrales-Leitsystem-proCflex-300x139.jpeg 300w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/zentrales-Leitsystem-proCflex-1024x473.jpeg 1024w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/zentrales-Leitsystem-proCflex-768x355.jpeg 768w\" sizes=\"auto, (max-width: 1280px) 100vw, 1280px\" \/><\/figure>\n\n<h3 class=\"wp-block-heading\">2. Structuring according to ISA-88 (S88)<\/h3>\n\n<p class=\"wp-block-paragraph\">A decisive step toward innovation was the systematic breakdown of the plant into standardized units according to ISA-88. The structure was divided into:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Units (parts of the system)<\/li>\n\n\n\n<li>Phases (process steps)<\/li>\n\n\n\n<li>Transfers (material movements)<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">This results in the following advantages:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>The structure replaces individual programming with a clearly defined model.<\/li>\n\n\n\n<li>Reusable process logic simplifies the implementation of similar workflows.<\/li>\n\n\n\n<li>This increases flexibility when adjusting recipes during operation.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">This standardized structure also serves as the methodological foundation for subsequent batch control and for the technical implementation of PLC sequence control.<\/p>\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"473\" height=\"1024\" src=\"https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/Strukturierung-nach-ISA-88-S88-473x1024.jpeg\" alt=\"\" class=\"wp-image-1454\" srcset=\"https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/Strukturierung-nach-ISA-88-S88-473x1024.jpeg 473w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/Strukturierung-nach-ISA-88-S88-139x300.jpeg 139w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/Strukturierung-nach-ISA-88-S88.jpeg 591w\" sizes=\"auto, (max-width: 473px) 100vw, 473px\" \/><\/figure>\n\n<h3 class=\"wp-block-heading\">3. Automatic Sequence Control in the PLC<\/h3>\n\n<p class=\"wp-block-paragraph\">Instead of traditional server-based control, a new approach was implemented: step chains are loaded completely into the PLC at the start of a job. <\/p>\n\n<p class=\"wp-block-paragraph\">This form of PLC sequence control shifts the actual execution directly to the control level. The PLC step chain thus becomes the operational carrier of the process logic. <\/p>\n\n<p class=\"wp-block-paragraph\">The implementation included:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Development of a step sequence controller as a matrix\/dispatcher<\/li>\n\n\n\n<li>Processing of several hundred phases per system<\/li>\n\n\n\n<li>Definition of standardized data structures for:\n<ul class=\"wp-block-list\">\n<li>Phases<\/li>\n\n\n\n<li>Transfers<\/li>\n\n\n\n<li>Functions<\/li>\n\n\n\n<li>Steps in the manufacturing instructions<\/li>\n<\/ul>\n<\/li>\n<\/ul>\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"473\" src=\"https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/Automatische-Ablaufsteuerung-in-der-SPS-1024x473.jpeg\" alt=\"\" class=\"wp-image-1450\" srcset=\"https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/Automatische-Ablaufsteuerung-in-der-SPS-1024x473.jpeg 1024w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/Automatische-Ablaufsteuerung-in-der-SPS-300x139.jpeg 300w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/Automatische-Ablaufsteuerung-in-der-SPS-768x355.jpeg 768w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/Automatische-Ablaufsteuerung-in-der-SPS.jpeg 1280w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n\n<p class=\"wp-block-paragraph\"><strong>The result is clear:<\/strong><\/p>\n\n<ul class=\"wp-block-list\">\n<li>The solution operates without permanent dependence on a central server.<\/li>\n\n\n\n<li>At the same time, the communication load between system components is minimized.<\/li>\n\n\n\n<li>Process steps are processed quickly and deterministically directly in the PLC.<\/li>\n\n\n\n<li>This makes production processes more stable and robust.<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\">4. Central Deployment Logic (\u201cDeploy to Clients\u201d)<\/h3>\n\n<p class=\"wp-block-paragraph\">A key innovation component for automating engineering was the central deployment logic. This supports the structured distribution of content defined in the MES. <\/p>\n\n<p class=\"wp-block-paragraph\">Implementation:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Development of a deployment engine within the MES<\/li>\n\n\n\n<li>Automatic transformation of phases defined in the MES:<br\/>into PLC programs (SIMATIC TIA Portal)\n<ul class=\"wp-block-list\">\n<li>in SPS-Programme (SIMATIC TIA Portal)<\/li>\n\n\n\n<li>and visualization structures (AVEVA InTouch)<br\/><\/li>\n<\/ul>\n<\/li>\n\n\n\n<li>Centralized rollout of:\n<ul class=\"wp-block-list\">\n<li>Recipes<\/li>\n\n\n\n<li>Process logic<\/li>\n\n\n\n<li>Visualization data<\/li>\n<\/ul>\n<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">The data flow is clearly defined:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>From MES \u2192 PLC \u2192 HMI<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">The benefits:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Manual programming is no longer required in this process.<\/li>\n\n\n\n<li>The data base remains consistent across all systems.<\/li>\n\n\n\n<li>This reduces the engineering effort throughout the project.<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\">5. Visualization and Operation<\/h3>\n\n<p class=\"wp-block-paragraph\">Operation is carried out via modern HMI systems using AVEVA InTouch. The visualization supports the operation and monitoring of processes and is closely linked to the PLC sequence control. <\/p>\n\n<ul class=\"wp-block-list\">\n<li>The system provides the live status of all plants in real time.<\/li>\n\n\n\n<li>A graphical process representation clearly depicts the processes according to S88.<\/li>\n\n\n\n<li>Alarm and event management support structured monitoring of operations.<\/li>\n\n\n\n<li>Operation is role-based and aligned with respective responsibilities.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">Implementation:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Development of S88-compliant graphical workflows<\/li>\n\n\n\n<li>Structured arrangement of function blocks for intuitive operation<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\">6. Automation of multiple production lines<\/h3>\n\n<p class=\"wp-block-paragraph\">The solution is not limited to individual system components but encompasses multiple production lines as well as additional peripheral equipment. This integrates the PLC sequence control beyond individual units into a comprehensive, end-to-end logic. <\/p>\n\n<ul class=\"wp-block-list\">\n<li>Integration of multiple production line systems<\/li>\n\n\n\n<li>Connection of filling systems<\/li>\n\n\n\n<li>Connection of peripherals, e.g., exhaust systems, process exhaust air\/purification, energy and media supplies such as nitrogen, water, and compressed air, including filling with labeling<\/li>\n\n\n\n<li>Consistent control logic across all lines<\/li>\n<\/ul>\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"1280\" height=\"591\" src=\"https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/Automatisierung-mehrerer-Produktionslinien-1.jpeg\" alt=\"\" class=\"wp-image-1461\" srcset=\"https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/Automatisierung-mehrerer-Produktionslinien-1.jpeg 1280w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/Automatisierung-mehrerer-Produktionslinien-1-300x139.jpeg 300w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/Automatisierung-mehrerer-Produktionslinien-1-1024x473.jpeg 1024w, https:\/\/www.proctec.de\/wp-content\/uploads\/2026\/06\/Automatisierung-mehrerer-Produktionslinien-1-768x355.jpeg 768w\" sizes=\"auto, (max-width: 1280px) 100vw, 1280px\" \/><\/figure>\n\n<h2 class=\"wp-block-heading\">Energiethemen<\/h2>\n\n<p class=\"wp-block-paragraph\">The consumption of media such as compressed air, electricity, cooling and heating energy, exhaust air, and raw materials is specifically recorded in the individual production steps and plant modules. <\/p>\n\n<p class=\"wp-block-paragraph\">The main objective is to log and optimize manufacturing processes with regard to material, energy, and media consumption. <\/p>\n\n<p class=\"wp-block-paragraph\">Consumption data is made available via an interface to the company\u2019s proprietary data acquisition system.<\/p>\n\n<p class=\"wp-block-paragraph\">In addition, a central order management system communicates with various other sub-systems, such as filling, packaging, and labeling. <\/p>\n\n<p class=\"wp-block-paragraph\">It continuously supplies these systems with relevant order data and provides the current order status at all times.<\/p>\n\n<p class=\"wp-block-paragraph\">All data is then stored internally and transferred to the company\u2019s own ERP system. <\/p>\n\n<p class=\"wp-block-paragraph\">Once an order is completed, all data is flexibly finalized. This applies both when an order is fully fulfilled and in the event of an interruption before the data is transferred to the company\u2019s internal order management system. <\/p>\n\n<h2 class=\"wp-block-heading\">4. Result: A Synchronized Integrated System Instead of Individual Solutions<\/h2>\n\n<p class=\"wp-block-paragraph\">The combination of traditional automation and new architecture has resulted in a significant technological leap. <\/p>\n\n<p class=\"wp-block-paragraph\">Previously separate structures have been transformed into a synchronized integrated system. The PLC sequence control is an essential component of the new overall architecture. <\/p>\n\n<h3 class=\"wp-block-heading\"><strong>Operational Benefits<\/strong><\/h3>\n\n<ul class=\"wp-block-list\">\n<li>Significantly reduced malfunctions<\/li>\n\n\n\n<li>Higher system availability<\/li>\n\n\n\n<li>Centralized control of all processes<\/li>\n\n\n\n<li>Fewer manual interventions<\/li>\n\n\n\n<li>Interventions are possible within certain limits in semi-automatic, manual, or service modes (e.g., manually controlling a flap) and are logged (value from, changed to)<\/li>\n\n\n\n<li>The higher-level safety control system ensures that processes are only permitted in defined states (safety takes precedence, ATEX compliance is paramount)<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\"><strong>Strategic Advantages<\/strong><\/h3>\n\n<ul class=\"wp-block-list\">\n<li>Flexible adaptation of recipes<\/li>\n\n\n\n<li>Faster implementation of new products<\/li>\n\n\n\n<li>Significantly reduced engineering effort<\/li>\n\n\n\n<li>Zukunftssichere Systemarchitektur<\/li>\n\n\n\n<li>Reduction in plant personnel through automated, flexible processes in dosing and mixing systems<\/li>\n<\/ul>\n\n<h2 class=\"wp-block-heading\">5. Conclusion<\/h2>\n\n<p class=\"wp-block-paragraph\">The combination of S88 standardization, a central MES, automatic deployment, a database, and an MES system, along with SCADA, HMI, and visualization solutions, creates a consistently structured production environment. <\/p>\n\n<p class=\"wp-block-paragraph\">Together with PLC-based process control, it forms the foundation for flexible, robust, scalable, and data-driven operations.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Vom klassischen Leitsystem hin zu einer intelligenten, S88-basierten Produktionsarchitektur As part of the expansion of a CP area at the Poing site, REMA TIP TOP AG faced the task of fundamentally upgrading its production architecture. The system was completely redesigned and implemented in close collaboration with plant manufacturers. Interfaces to third-party control systems were not [&hellip;]<\/p>\n","protected":false},"featured_media":2036,"menu_order":0,"template":"","referenzen_category":[25],"class_list":["post-2025","referenzen","type-referenzen","status-publish","has-post-thumbnail","hentry","referenzen_category-automotive-industry"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.0 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>PLC Sequence Control: Modern Production Architecture in Action<\/title>\n<meta name=\"description\" content=\"\u25ba Learn how an S88-based architecture, combined with MES, deployment, and PLC process control, can make production processes flexible and robust.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.proctec.de\/en\/references\/case-study-rema-tip-top-ag-plc-sequence-control-with-s88-architecture\/\" 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