ICP DAS integrates real-time monitoring systems in food factories, including powder weighing, oil tank overflow monitoring, factory temperature and humidity monitoring, and control room equipment and environmental monitoring. This enables remote centralized management and the establishment of comprehensive production records.

The AVEVA Edge SCADA system retrieves monitoring data via Ethernet, including PLC data from the weighing system collected by the PDS Series Programmable Serial-to-Ethernet Device Server, personnel access records from the ACS Series Card Reader, oil tank overflow alerts from the WISE Series I/O Module, temperature and humidity data integrated by the MDC-700 Series Modbus Data Concentrator, and control room equipment and environmental data gathered by the uPAC-7186EX Programmable Automation Controller (PAC). With this seamless integration, management can efficiently oversee the entire factory through a unified monitoring platform.

Introduction:

In recent years, recurring food safety incidents have sparked widespread public concern. To protect consumers, governments worldwide have tightened regulations, enforcing strict standards across all stages of food production—from manufacturing and processing to formulation, packaging, transportation, storage, and sales. In this regulatory landscape, food manufacturers must not only ensure precise monitoring of production processes but also provide comprehensive production traceability, driving an increasing need for data and system integration.

The customer in this case is a food factory in Taiwan. While the factory had existing powder weighing and temperature/humidity monitoring systems, the data was scattered across different systems, lacking integration and centralized management. This made it difficult to trace production issues in the event of a food safety incident. To resolve this, the customer sought a system integration solution for real-time, centralized monitoring of raw materials and environmental parameters, including precise tracking of powder weighing, machine utilization, oil tank overflow, factory temperature and humidity, and control room environmental data. By implementing this solution, the factory aimed to establish comprehensive production traceability and enhance product safety.

ICP DAS System Integration Solution: Building a Comprehensive Production Traceability System

The system structure is divided into five sections: powder weighing monitoring, oil tank overflow monitoring, factory temperature and humidity monitoring, factory access control, and control room equipment and environmental monitoring.

First, the weighing monitoring system tracks the output weight of powder and the utilization of production machines. The PDS-734 Programmable Serial-to-Ethernet Device Server enables PLCs using the RS-422 communication interface to connect to an Ethernet network, allowing the SCADA system to retrieve production data from the PLCs via Ethernet.

In the oil tank overflow monitoring system, the customer uses the WISE-7144 Intelligent I/O Module to read digital input (DI) signals from the oil tank’s float level switch and transmit the data to the SCADA system via Ethernet.

In the temperature and humidity monitoring system, the customer uses the MDC-711 Modbus Data Concentrator to aggregate environmental data from multiple on-site temperature and humidity sensors. The SCADA system then retrieves this data via Ethernet.

In the factory access control monitoring system, the ACS-11-MF Proximity Card Reader with Keypad manages access control information for each area, ensuring precise records of personnel responsible for each production batch. The data is then transmitted to the SCADA system for centralized management.

In the control room monitoring system, the customer uses the uPAC-7186EX Palm-size MiniOS7 Programmable Automation Controller (PAC) to convert UPS data, originally transmitted via a proprietary protocol, into the standard Modbus TCP communication protocol for integration with the SCADA system. Additionally, the customer installs DL-10 Temperature and Humidity Sensors in the control room to monitor environmental conditions, with both sensor data and air conditioning parameters centrally managed by the SCADA system.

The system structure is as follows:

• Weighing System Monitoring:

  The PDS Series Programmable Serial-to-Ethernet Device Server features a gateway function that converts Modbus TCP to Modbus RTU/Modbus ASCII, enabling RS-232/485/422 serial devices to connect to an Ethernet network. It also supports most SCADA and HMI systems that use the Modbus TCP protocol. In this case, the PDS-734 Programmable Serial-to-Ethernet Device Server facilitates network connectivity for the PLC, allowing it to transmit weighing data and machine availability information back to the SCADA system via Ethernet.

• Oil Tank Overflow Monitoring:

  The WISE-7144 Intelligent I/O Module features 8 digital input (DI) and 8 digital output (DO) channels, with each DI channel supporting counter functionality. It supports the Modbus TCP communication protocol, enabling seamless integration with SCADA systems. The WISE-7144 also includes an IF-THEN-ELSE logic engine, allowing for stable execution of automation logic. Even if communication with the central control system is interrupted, the WISE-7144 can perform edge computing on-site and supports email notifications and CGI command transmission. When operating WISE series modules, no programming is required; users can easily configure control logic through the built-in HMI interface with simple mouse clicks, significantly reducing system development costs. In this case, the WISE-7144 reads DI signals from the oil tank float level switch and transmits the data to the SCADA system via Ethernet.

• Temperature and Humidity Monitoring:

  The MDC-700 Series Modbus Data Concentrator provides RS-232, RS-485, and Ethernet ports, allowing Modbus devices with RS-232 and RS-485 ports to connect to Ethernet. The MDC-700 Series follows user-defined commands to sequentially read data from Modbus slave devices connected to the COM Ports. The data read back from different slave devices will be combined into a continuous address format. This allows a host computer to read the data of multiple slave devices at one time for unified management, replacing the previous time-consuming polling method, thereby improving overall system performance.

  In this case, the customer uses the MDC-711 Modbus Data Concentrators to collect and integrate data from multiple RS-485 temperature and humidity meters, then transmits all the data to the control room via Ethernet at one time.

• Factory Access Control:

  The ACS-11-MF Proximity Card Reader with Keypad integrates door access control, audio instructions, and floor control functions. It supports Ethernet and RS-485 communication interfaces, enabling remote card number issuance and entrance record uploads. Additionally, it features tamper detection and door position monitoring alerts, enhancing the security of access control systems and improving management efficiency. In this case, the ACS-11-MF is responsible for factory access control and transmits personnel attendance data to the SCADA system for unified management.

• Control Room Monitoring:

  The DL-10 Temperature and Humidity Sensor measures temperature, humidity, and dew point. It supports the RS-485 communication interface (Modbus RTU protocol) for real-time data transmission. With its compact size (25 x 20.2 x 30mm), the DL-10 saves installation space significantly and can be easily mounted anywhere. In addition, ICP DAS provides the DCON Utility Pro software for users to configure the DL-10 module via a user-friendly interface. In this case, the DL-10 measures temperature and humidity data in the control room to ensure a stable environment.

  The uPAC-7186EX-G Palm-size MiniOS7 Programmable Automation Controller (PAC) is equipped with an 80186 CPU (80MHz) and supports various communication interfaces, including Ethernet, RS-232, and RS-485. Additionally, it features an I/O expansion bus that allows for the addition of various I/O functions, including DI, DO, A/D, D/A, Timer/Counter, as well as multiple communication interfaces such as RS-232/422/485 and CAN. Users can easily connect serial devices to a network and communicate with SCADA systems via the standard Modbus communication protocol using ICP DAS’s software development toolkits, including the MiniOS7 framework and Modbus library.

  In this case, the uPAC-7186EX-G connects the DL-10 temperature and humidity sensors, air conditioning system, and UPS in the control room to the network and transmits the data to the SCADA system for centralized management.

  AVEVA Edge is a comprehensive platform that provides fundamental tools for creating robust SCADA and HMI applications. It supports all Windows runtime platforms, including Windows Embedded Compact, Windows Embedded Standard, Windows 8.1/10/11, and Windows Server Editions (Server 2012/2016/2019). In addition to facilitating local operations, AVEVA Edge enables remote web page monitoring, enhancing both convenience and usability.

  In this case, AVEVA Edge integrates all monitoring data from the factory, allowing operational personnel to view critical information, including weighing data, production progress, oil tank overflow status, factory temperature and humidity, access control information, and control room equipment and environmental data—all from one overview interface. This eliminates the need for manual data integration, significantly enhancing management efficiency and facilitating the implementation of a comprehensive production traceability system.

Benefits:

1. With ICP DAS’s VxComm Utility, the built-in COM Port of the PDS Series Programmable Serial Device Server can be mapped as a standard COM Port on the host computer, allowing the SCADA system to easily access data from serial devices. Additionally, the PDS Series modules feature the high-performance MiniOS7, enabling a rapid one-second boot time and enhancing overall operational efficiency.
2. The WISE-7144 Intelligent I/O Module supports Power over Ethernet (PoE), allowing it to receive power directly through an Ethernet cable, reducing the need for extra wiring and power outlets. This simplifies system design and enhances flexibility. In non-PoE network environments, the WISE-7144 can be powered via a power adapter or batteries.
3. The MDC-700 Series Modbus Data Concentrator supports up to 8 Modbus TCP masters, allows the configuration of up to 250 Modbus RTU commands, and enables the collection and management of up to 9600 records for each DI, DO, AI, and AO data type. No software installation or programming is required, as the MDC-700 Series features a built-in web server. Users can easily configure settings and monitor the system via a web browser, enabling remote access for monitoring and maintenance. This ensures a highly convenient operation and management experience.
4. The MDC-700 Series Modbus Data Concentrator supports CSV file configuration, enabling editing in spreadsheet software or plain-text editors. Users can edit Modbus RTU commands in a CSV file and then import it into the MDC-700 Series, enabling simultaneous modifications of Modbus RTU commands for multiple slave devices. This significantly streamlines device management, saving time and improving efficiency.

ICP DAS’s Energy Management System (EMS) Solution: Cutting Electricity Costs for Businesses

With growing attention on energy conservation and carbon reduction—alongside rising electricity costs—many businesses are actively seeking effective energy-saving solutions. However, before implementing energy management and carbon emission controls, companies must first gain a comprehensive understanding of their facility’s energy consumption.

ICP DAS’s energy management solution enables businesses to accurately monitor energy consumption across the production process, including cooling towers, chillers, HVAC systems, lighting, and key manufacturing equipment. By analyzing collected power usage data, companies can implement targeted energy-saving measures, effectively minimizing unnecessary power consumption and reducing electricity costs—leading to substantial savings.

• Factory Power Data Collection

  The PM-3000 Series Smart Power Meter accurately records power consumption data from various equipment, such as dryers, compressors, oil tank heaters, and mixing machines used in food manufacturing. With built-in communication capabilities, the PM-3000 Series transmits power data via the Modbus RTU protocol to the PMC Series Power Meter Concentrator for seamless data integration.

• Power Meter Concentrator with Edge Computing and Control Capabilities

  The PMC Series Power Meter Concentrator provides comprehensive and flexible power meter integration, enabling real-time monitoring, recording, and management of equipment power consumption. Its user-friendly design allows access to power data and system configuration directly via a web browser.

  With built-in IF-THEN-ELSE statement, the PMC Series can automatically send alerts via email, SMS, Telegram, or WeChat when abnormal voltage or current levels are detected, allowing for early issue resolution and preventing unexpected downtime. In this case, after consolidating power consumption data from the factory and equipment, the PMC Series transmits the data to central control software via the Modbus TCP protocol for streamlined management.

• Cloud Monitoring and Visualization Management

  IoTstar, an IIoT cloud management software developed by ICP DAS, is designed for monitoring and managing PMC/PMD/WISE series controllers along with their connected I/O modules and equipment. With IoTstar, maintenance personnel can remotely monitor various stages of production and visualize key data—such as voltage, current, power factor, cumulative energy consumption (kWh), and carbon emissions—through an intuitive dashboard.

  Additionally, IoTstar’s reporting feature enables users to generate reports in PDF or Excel formats, facilitating energy efficiency tracking and analysis. By fully integrating ICP DAS’s energy management solution, factories can achieve both high operational efficiency and significant energy savings.

Conclusion:

ICP DAS, with its diverse product lines—including Programmable Serial-to-Ethernet Device Servers, Intelligent Edge Controllers, Modbus Data Concentrators, Programmable Automation Controllers, and Smart Power Meters—delivers comprehensive system integration and energy management solutions.

In food factories, ICP DAS enables real-time remote monitoring and centralized management of powder weighing systems, oil tank overflow detection, factory temperature and humidity, power systems, and control room equipment and environments. These technologies effectively solve challenges related to fragmented production data and lack of integration, helping establish a more complete production traceability system. This not only enhances business competitiveness but also ensures stringent quality control for consumer safety.

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October 21, 2025