Customer Case Studies

Air Liquide implemented Cogent DataHub as part of a Modular Procedural Automation strategy to unify diverse control systems and optimize operations across air separation units. Acting as an OPC gateway, Cogent DataHub bridged legacy OPC DA systems with modern OPC UA controllers while introducing conditional logic to prevent unsafe or unintended data writes. This architecture improved system reliability, reduced startup time by over 60 percent, and increased production, including more than 500 additional tons of liquid oxygen. The solution also enhanced scalability, enabled centralized control, and provided a reusable framework for secure, efficient data integration across facilities.

A global beverage manufacturer implemented TOP Server's Allen-Bradley Suite and OPC Router to modernize data integration between Rockwell Automation PLCs and SAP. The solution replaced inefficient legacy communication methods with secure, real time data transfer using OPC UA, while introducing optimized trigger-based logic to ensure accurate and efficient data flow. This approach eliminated redundant processing, improved system performance, and enabled seamless automation of workflows, resulting in enhanced traceability, increased operational efficiency, and a scalable foundation for future growth.

Namibia Brewing Ltd. implemented a power management system built on TOP Server's Modbus, SNMP, and Siemens Driver Suites and Cogent DataHub to feed data into AVEVA Historian and monitor their Windhoek site via a browser interface. This allows them to monitor the output and efficiency of their solar panels, ensure their facility has electricity even when their local power grid has a problem, and ensure water is being used efficiently.

A leading UK retailer used OmniServer to modernize legacy systems in high volume distribution centers without replacing existing equipment. OmniServer enabled communication with outdated devices by converting proprietary protocols into OPC data. This approach enabled real time visibility into operations, improved order fulfillment efficiency, reduced freight waste, and enhanced decision making through detailed performance tracking, all while ensuring long term reliability, scalability, and zero downtime.

An aluminum smelting operation that had doubled in size since it first opened implemented Cogent DataHub to connect multiple OPC DA and OPC UA servers to an Oracle database and MES system hosted on a Linux machine. This allowed them to improve the integration of real-time operational data with their MES system in the cast house operation and reduce risk, with the DataHub acting as a real-time hub to provide fast and efficient concentration and distribution of data.

BP Pipelines used Cogent Datahub to connect their SCADA system with a leak detection application by bridging data between a real time Sybase database and an OPC server. After struggling to find a compatible ODBC solution, Datahub enabled reliable data flow through custom scripting, allowing seamless integration, real time data access, and flexible system control. The solution also supported dynamic failover between primary and backup servers through the use of DataHub's Redundancy feature, as well as live updates to data logging into an Oracle database, improving operational efficiency and system reliability.

At the Mukhaizna oil field in Oman, Cogent Datahub was implemented alongside TOP Server to optimize OPC communication and improve system performance. As the number of tags grew to nearly 30000, inefficient data requests from the HMI created performance bottlenecks. By introducing Cogent Datahub as an intermediary OPC client, the system shifted to change based data updates, significantly reducing load and improving speed. The solution also enabled secure OPC tunnelling over TCP, centralized data aggregation across eight facilities, real time and historical data logging to PI and SQL databases, and advanced features such as redundancy, system monitoring, and integration with legacy systems, ultimately enhancing scalability, reliability, and operational efficiency.

A leading energy producer implemented a tiered architecture leveraging TOP Server and OPC Data Client to securely move data across Business, DMZ, and Automation layers via OPC UA, enabling seamless access to operational data without exposing underlying systems. This approach improved control over data flow, allowing business applications to reliably access real-time data from field devices and supporting optimization workflows across engineering and operations teams, while maintaining strict network segmentation and security requirements.

Amcor implemented TOP Server across 25 plants to standardize industrial data connectivity, enabling real time visibility and improved operational efficiency in support of its sustainability goals. By integrating data from diverse control systems into a unified platform, Amcor reduced waste, lowered energy consumption, and improved performance, achieving gains such as increased OEE and faster production cycles. The scalable, common infrastructure simplified engineering, reduced costs, and enabled faster deployment of analytics and AI models, helping Amcor move toward its net zero and recyclable packaging targets.

A leading provider of packaging equipment for aseptic beverage cartons utilizes the TOP Server OPC Client Suite to enable secure, reliable, and platform-independent data exchange, as well as both machine-to-machine and shop floor to top floor communication. By using OPC-based communication, the organization supports integration across diverse equipment, PLCs, and production systems, helping enable connected and flexible manufacturing environments.

A major pharmaceutical company used LGH File Inspector from Software Toolbox to replace fragile Excel based data extraction from AVEVA InTouch LGH files. The solution enabled utilities teams to easily access and export historical data without relying on macros or engineering support, improving accuracy and maintaining cybersecurity compliance. As a result, the company eliminated recurring reporting disruptions, streamlined monthly compliance workflows, and gained over 250 hours of engineering time, while increasing operational efficiency and user autonomy.

A major biotechnology company implemented OPC Router’s OPC UA and REST plug-ins to integrate data across existing platforms and systems. By enabling secure, real-time data exchange between OPC UA sources and RESTful services, the solution improved visibility into critical test result data across the facility. This approach ensured that vital information is consistently available where and when it is needed, supporting better decision-making, streamlined operations, and a more connected data infrastructure.

TOP Server's Building Automation and Manufacturing Suites serve as the foundation of the Data Center Infrastructure Management (DCIM) system for one of the world’s largest digital infrastructure and colocation data center providers, allowing them to integrate with UPS systems, building automation sensors, battery systems, and electrical panels to collect and centralize critical operational data. This unified data environment enables the organization to monitor and manage uptime across its facilities while providing a single source of truth for both internal teams and external customers, empowering stakeholders to visualize site usage, capacity, and performance in real time via hyperscalers including AWS and Google.

A provider of a wide range of internet and cloud-based solutions implemented TOP Server to unify data from power, cooling, and facility systems across its data center infrastructure. This enabled real-time visibility into energy usage and system performance, supporting more efficient operations. By aggregating and standardizing data, the organization optimized load distribution, reduced resource consumption, and identified inefficiencies more effectively, supporting the user's sustainability initiatives.