Process optimization, today, is a key factor for any manufacturing organization to reduce the time of production cycles, increase product quality, and reduce costs.

Armal has injection molding machines that produce plastic components of different sizes. Each machine has an average lifetime of 15-20 years, however, at the production level they are still in good condition. Concurrently, Armal needed to modernize their entire workflow in order to remotely monitor the machines and optimize their production. In the past, they used Arduino boards, but data losses occurred often, and the monitoring process was not reliable.

The Zerynth team provided Armal with an Industrial IoT Platform for real-time monitoring for power consumption of their industrial machines and the entire production cycle.

An Edge Device was installed on each machine to collect 4 signals in retrofitting mode. Thanks to this collection of signals and their derivatives, Armal is now able to monitor their entire production flow from simple dashboards with the purpose of making machine data easily analyzed by Management, and being able to make strategic decisions. A monitoring system for the lighting system in the production plant was also implemented in order to optimize energy consumption.

Armal has successfully completed its digitalization journey by obtaining an IoT solution capable of real-time power consumption monitoring for each machine. Thanks to this process, the costs for energy consumption of their machinery has been reduced by 60% compared to the earlier technologies used, and by 40% compared to the previous generation. In only 1.5 years Armal recovered their implementation costs. Moreover, in only 4 months their investment, made in IoT technology, was recovered.