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 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.

A leading UK retailer used OmniServer and OPC Data Logger from Software Toolbox 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 OmniServer enabled communication with outdated devices by converting proprietary protocols into OPC data, while OPC Data Logger captured and stored operational data in a SQL database for analysis. This approach delivered 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.

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, 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, the 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.

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 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.