Case studies

Maintaining high cleanliness standards in food production requires modern and reliable solutions. In response to growing regulatory demands and operational needs, one of our specialists carried out a project to modernize the CIP (Clean In Place) station in a production facility. The goal was to transition from a manual, time-consuming process to a fully automated system that meets the latest legal and technological requirements. By implementing modern solutions, we not only streamlined operations but also enabled precise parameter control, process documentation, and real cost savings in daily plant operations. The results of the implementation demonstrated the vast potential of automation—both in terms of efficiency and compliance with industry standards.

The modernization of the CIP cleaning station delivers measurable results from the very first days after implementation. Process automation not only shortens cleaning time but also improves quality, consistency, and overall process reliability. The production facility gains greater control over the cleaning process and the ability to quickly respond to any irregularities.

1. 60% reduction in cleaning time,
2. Lower consumption of water, energy, and detergents,
3. Full compliance with legal regulations,
4. Automatic reporting of each cycle,
5. Improved repeatability and cleaning quality.

The optimized system enables precise control and monitoring of process parameters, as well as real-time tracking of critical values such as chemical concentration and rinsing time.

CIP process automation eliminates many common issues associated with manual or partially automated cleaning. It significantly reduces the risk of incomplete cleaning due to human error and inaccurate chemical dosing. The system ensures full control over key parameters—rinsing time, temperature, and detergent concentration—greatly enhancing the consistency and effectiveness of the cleaning process. With automatic reporting, the need for manual cycle documentation is eliminated. Additionally, access control and user authentication allow for tracking and identifying personnel making changes in the system. Importantly, the system ensures full compliance with EU Regulation 2017/625 of March 15, 2017.

The implementation of an integrated system based on modern industrial automation technologies includes several technical solutions applicable to the CIP cleaning station.

These include:

1. Replacing manually operated valves with automated valves
2. Upgrading the PLC controller to the Siemens S7-1500 model
3. Using Profinet communication modules for improved connectivity
4. Designing the control system in the EPlan environment

Additionally, the system features an HMI panel for entering cleaning recipes, visualization, and process control, along with an RFID reader for user authentication. The system also supports automatic report generation for each cleaning cycle.

Modernizing the CIP cleaning station with advanced industrial automation solutions significantly enhances hygiene, control, and efficiency in production processes. The implementation of cutting-edge technologies ensures full control over every stage of the cleaning process, resulting in improved consistency and compliance with legal regulations. Integrating the system with reporting and user authentication functions increases transparency and operational oversight. The findings from this project highlight that CIP station automation is a real solution to the challenges faced by production plants.

Boost Efficiency and Hygiene Standards in Your Facility! Don’t wait until outdated processes impact your product quality and production costs. Choose modern automation and gain greater control, cost savings, and full regulatory compliance. Contact us today—together, we’ll find the best solution for your production needs!

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Automated utility monitoring is a powerful tool for cost reduction, increased efficiency, and regulatory compliance. Implementing smart meters, a SCADA system, and integrated energy management systems (EMS) in a production facility enables rapid identification of losses, consumption optimization, and reduced downtime risks. 

1. 15% reduction in energy costs achieved through loss elimination and optimized use of electricity, water, and gas. 
2. Increased energy efficiency through optimized equipment operation.
3. Rapid failure and anomaly detection, lowering the risk of downtime by 10%. Full compliance with CO₂ emissions monitoring and utility consumption regulations. 
4. Enhanced production planning with real-time data analysis. 
5. Improved transparency and control over energy costs. 

• Lack of control over actual utility consumption. 
• Delays in detecting failures and leaks.
• Challenges in CO₂ emissions reporting in compliance with regulations.
• Inefficient energy cost management.

Smart meters and sensors monitor consumption in real time, while the SCADA system automatically analyzes data, generates reports, and sends alerts in case of anomalies. Integration with the EMS system enables automatic adjustments to equipment operation, eliminating losses and improving production stability. 

Don’t let inefficient utility consumption drive unnecessary costs. Contact us to learn how modern solutions can benefit your company! 

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PyTango is a Python library that enables communication with the Tango Controls system, a tool used to develop distributed control systems in scientific laboratories such as ESRF, SKAO, MAX IV, and ELETTRA. A bug was discovered in PyTango that remained unresolved for eight years, with repeated attempts to fix it ending in failure. Mateusz Celary from S2Innovation managed to resolve it in just three days—thanks to in-depth code analysis and an unconventional approach: dynamically overriding a function pointer in Boost::Python. This is a story of determination, code analysis, and overcoming organizational constraints.

The main challenge was fixing a bug in PyTango that had remained unresolved for years despite numerous attempts to eliminate it. The issue was related to memory management at the interface between C++ and Python, making it difficult to control object lifecycles.

The PyTango developers had no effective way to solve the problem, and previous approaches had failed. An additional challenge was the time pressure—there were only three days to analyze the issue and determine whether a fix was even possible.

We focused on in-depth code analysis and intensive debugging using GDB. The key was to fully understand the memory management mechanism between the C++ and Python layers, which allowed us to pinpoint the root cause of the bug.

When standard methods failed, we made a bold but effective decision—we applied dynamic function pointer overriding in Boost::Python. This allowed us to control class destructors from Python, enabling more efficient object lifecycle management and eliminating memory-related bugs.

Technologies used: Python, C++, Boost::Python, GDB. However, the key factors in solving the issue were analytical thinking and a creative approach, which enabled precise diagnostics and an effective fix.

Our solution restored system stability and enabled proper memory management between Python and C++. We fixed a critical command that other programs depended on, and in the process, deepened our understanding of PyTango’s inner workings.

Additionally, the implementation of automated tests further increased system reliability and established a solid foundation for future improvements.

The PyTango story shows that even long-standing unresolved bugs can be eliminated through creativity and flexibility in tackling technical challenges. Innovative memory management not only solved the problem but also opened up new opportunities for system optimization.

Do you have an unresolved issue in your code? Our unconventional approach could help you too. Contact us!

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The European Spallation Source (ESS) is a multidisciplinary research facility based on the world’s most powerful neutron source. The center employs cryogenic cooling systems for cryomodule testing. As operations expanded, the need for improved supervision and the elimination of manual workloads became evident. To address this, the Automated Control Sequence (ACS) was implemented, automating processes and enhancing precision and efficiency.

By automating repetitive processes, ACS significantly streamlined the handling of cryogenic cooling operations and improved supervision at every stage. Operators can now focus more on data analysis and system optimization rather than routine equipment control. Automation increased operational precision, ensuring stable cooling parameters and eliminating inconsistencies.

Thanks to an intuitive graphical user interface (GUI), users have complete control over the process, and real-time data visualization facilitates quick decision-making. The system is designed for future expansion—the next planned update includes replacing Excel as the database to enhance efficiency.

Previously, each device required a dedicated operator. With 27 cryomodules being cooled simultaneously, this created significant organizational and technical challenges. Manual operation of so many modules would have required multiple operators or placed excessive strain on a single person, leading to delays and inconsistencies.

The lack of centralized coordination made synchronization difficult, as operators had to repeatedly perform the same tasks, wasting time on routine operations. With the increasing number of devices, the risk of human error grew, and manual control did not allow for precise parameter adjustments. Automating the cooling process was essential to improve operational consistency and reduce excessive personnel involvement.

The Automated Control Sequence (ACS) was developed to fully automate cryomodule control, eliminating the need for manual operation. Each module was equipped with a dedicated PLC controller, while a master unit coordinates their operation, ensuring process synchronization. Integration with EPICS allows real-time monitoring of parameters and instant responses to changing conditions.

To execute the project:

• Siemens PLC controllers were programmed using TIA Portal.
• Python scripts were used to automatically generate PLC code, reducing update time significantly.
• The Phoebus environment was used to develop the user interface, providing operators with easy access to system status information.
• The interface also enabled intuitive visualizations, supporting operational decision-making.

Initially, Excel was used as the database for storing operational sequences. However, due to the growing project scale, it is planned to be replaced with a more efficient data management system for better future modifications and ACS optimization.

The implementation of ACS at ESS optimized cryogenic cooling control, improving repeatability and reliability. Automation reduced routine tasks performed by operators, minimizing errors and enhancing system consistency. Future improvements include integrating a more efficient database, which will further streamline information management and system development.

Thinking about process automation? Start by analyzing your current procedures and choose a flexible control system that grows with your business. Implement solutions that speed up operations and boost efficiency. Contact us to learn how we can help automate your process!

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