Improving Environmental Compliance & Visibility at a Chemical Facility

Solutions: OT networking, third party equipment integration, data historization, reporting, alerts, operator visibility

The Challenge

A large chemical manufacturing facility producing liquid and powder-based products for commercial and industrial markets faced increased scrutiny around environmental data collection and reporting. State environmental regulators required clearer proof that critical emissions control systems were operating as designed, both in real time and historically.

Two areas were of particular concern:

1. A Regenerative Thermal Oxidizer (RTO) used to destroy hazardous airborne compounds

2. A Powder Production Area, where airborne particulates must be tightly controlled due to health, environmental, and process safety concerns

While the equipment itself was in place, the facility lacked consistent, accessible data to demonstrate compliance, verify system performance, and respond quickly if conditions went out of specification.

The Solution

Cybertrol partnered with the site to modernize data collection and improve environmental visibility across both areas without disrupting existing operations.

RTO Monitoring and Reporting

• Integrated the RTO controls into the plant’s SCADA environment

• Historized key operating parameters, including rolling temperature averages critical to regulatory compliance

• Created clear trend displays to show RTO performance at any point in time

• Implemented automated email alerts to notify teams if the RTO goes offline or operates outside approved limits

Example trend view illustrating continuous monitoring of emissions control system performance.

Powder Room Environmental Monitoring

• Integrated multiple dust collection and filtration systems into the control network

• Monitored approximately ten critical differential pressure and performance values

• Delivered centralized trends and dashboards that simplify operator verification

• Historized environmental data for long-term review by site personnel and regulators

Example of powder room environmental trends showing historical monitoring.

Across both projects, Cybertrol handled:

• Safe integration of multiple OEM PLCs

• Control system modifications to collect and historize data without impacting previously validated control logic

• Manufacturing Intelligence reporting designed for non-engineering users

• OT solutions for alerting, communication failure detection, and equipment status notifications

The Results

• Improved regulatory confidence with clear, historical proof of environmental system performance

• Easier compliance readiness, allowing on-demand reporting instead of manual data gathering

• Greater operational awareness through real-time visibility and automated alerts

• Faster response to abnormal conditions, enabling issues to be identified and addressed before they escalate

• Reduced risk of unnoticed environmental excursions or communication failures

• Better support for operators, with simple visuals replacing manual checks

By connecting environmental systems to actionable data, the facility gained confidence in its ability to adhere to compliance requirements.

Supporting Sustainability Through Smarter Data

Environmental responsibility doesn’t stop at installing the right equipment. It requires visibility, accountability, and accessible data. By combining OT networking, data historization, and user-friendly reporting, Cybertrol helps manufacturers turn environmental monitoring into a proactive, manageable process.

Environmental responsibility starts with visibility. Talk with Cybertrol about monitoring and reporting solutions that support compliance and long-term sustainability goals.