1. The Problem

Fisheries needed to modernize their plant-wide SCADA system to control and monitor complex fish processing operations including water quality management, temperature control, holding tanks, cookers, presses, decanters, centrifuges, and post-production storage machinery. The facility, processing 35-40% of the annual U.S. Gulf Menhaden catch, lacked integrated monitoring across diverse equipment and protocols, risking fish mortality, production inefficiencies, and regulatory compliance issues. Legacy systems couldn't provide reliable data integrity, real-time alerting, or multi-protocol communications essential for maintaining optimal fish processing conditions throughout the operation.

2. The Solution

FactoryStudio powered by FrameworX provided comprehensive monitoring and control for the entire menhaden fish processing operation, automating crucial processes including water quality management, temperature monitoring, oxygen level control, and production equipment oversight. The system collects real-time data from sensors throughout the facility, displays it on intuitive graphical interfaces, and provides automated alerts to optimize operations from raw fish handling through final fishmeal and fish oil production.

Simple Architecture Diagram:


Fish Processing Equipment     →      Multiple Communication Protocols
(Cookers, Presses, Decanters,         (ControlLogix, Automation Direct
Centrifuges, Conveyors)                    ECOM, Modbus Ethernet)
                ↓                                          ↓
      FactoryStudio FrameworX SCADA System
                ↓                                           ↓
    20+ Operator Workstations            Management Dashboards
    (3-6 monitors each)                        (Production Tracking)

Technical Specifications:

  • Industry: Food & Beverage (Fish Processing)

  • Location: Los Angeles (Processing 35-40% of annual U.S. Gulf Menhaden catch)

  • Communication Protocols: ControlLogix, Automation Direct ECOM, Modbus Ethernet

  • Scale: 20+ operator workstations with 3-6 monitors each, 10,000+ communication points

  • Equipment Monitored: Water quality sensors, temperature/oxygen transmitters, combustion systems, conveyors, VFDs, MCCs, pressure transmitters, cookers, presses, decanters, centrifuges, automated feeding systems

  • Development Timeline: Couple of months across multiple project phases

3. Key Enablers

  • Multi-Protocol Communication Support: Native drivers for ControlLogix, Automation Direct ECOM, and Modbus over Ethernet enabling seamless device integration across water quality sensors, temperature transmitters, and processing equipment

  • Real-Time Data Collection & Alerting: Automated monitoring of critical parameters with instant alerts for abnormal conditions, preventing fish mortality and equipment failure while enabling rapid response capabilities

  • Live Update Capability: Ability to update plant pages and graphics without server restarts, ensuring continuous operations during system modifications

  • Microsoft .NET Framework Integration: Ensuring future compatibility and sustainable operations management with modern technology stack

  • Robust Redundancy Architecture: Zero data loss design ensuring continuous monitoring of critical fish processing parameters

  • Scalable Platform: Support for 20+ operator workstations and 10,000+ communication points across the entire facility

4. The Results

  • Achieved zero data loss through robust redundancy architecture ensuring continuous monitoring of critical fish processing parameters

  • Enhanced operational efficiency through automated monitoring of water quality, temperature, and processing conditions across 10,000+ communication points

  • Improved sustainability with optimized resource management reducing waste and environmental impact throughout the processing workflow

  • Enabled remote monitoring capabilities allowing operators to manage operations and receive alerts from anywhere, improving response times

  • Delivered comprehensive traceability with historical data logging for detailed analysis, performance tracking, and regulatory compliance reporting

  • Reduced fish mortality and equipment failure through real-time alerting on abnormal conditions

  • Streamlined operations across 20+ operator workstations with multi-monitor setups for complete facility visibility

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