Solutions: OT networking, third party equipment integration, data historization, reporting, alerts, operator visibility
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.
A Regenerative Thermal Oxidizer (RTO) used to destroy hazardous airborne compounds
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.
Cybertrol partnered with the site to modernize data collection and improve environmental visibility across both areas without disrupting existing operations.
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.
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.
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
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.
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.