Industrial telemetry for CIGS PV manufacturing — Roltec / FDW
Smart Factory SCADA
Designed and implemented a continuous 24/7 SCADA and telemetry architecture for Poland's first CIGS thin-film PV manufacturing facility. Unified PLC devices (OPC UA, Modbus, PROFINET), Telegraf/InfluxDB Historians, and remote HMI access into a unified industrial backbone.
- Layers
- SCADA, concentrator, historian, ops apps
- Protocols
- OPC UA, Modbus, PROFINET
- Reliability
- Edge buffering, retries, offline recovery
- Integrations
- ERP, MES, EMS, IoT, BI
Industrial digital ecosystem
A fully integrated platform for modern manufacturing: SCADA, intelligent concentrators, Historian infrastructure, and production-support applications in one scalable operational environment.
The ecosystem enables real-time monitoring, process optimization, predictive analytics, and centralized industrial data management across the production backbone.
SCADA layer
Real-time industrial control
The SCADA environment is the operational control center. It provides:
- real-time visualization of production processes,
- monitoring of machines and industrial devices,
- alarms and event management,
- process supervision and remote operational control,
- KPI dashboards and operational analytics.
The system integrates directly with PLCs, sensors, industrial gateways, energy systems, and external production environments.
Intelligent concentrator
The concentrator is the communication and data orchestration engine between field devices and higher-level systems.
Responsibilities
- collecting telemetry from field devices,
- protocol translation and normalization,
- buffering and queue management,
- retry and failover handling,
- edge processing and validation,
- secure transmission to SCADA and Historian.
Protocols
- MQTT, OPC UA, Modbus TCP/RTU,
- HTTP APIs, raw TCP, and custom industrial protocols.
Designed for high availability: on communication failures the concentrator uses Redis-based buffering and PostgreSQL archival fallback to prevent data loss and resync after recovery.
Historian infrastructure
Long-term industrial data storage, indexing, and analytics:
- high-frequency time-series storage,
- historical trend analysis and process replay,
- production efficiency analytics,
- audit and compliance support,
- integration with reporting and BI systems.
Raw industrial signals become actionable engineering and business insight.
We unified SCADA, concentrators, historian, and operational apps into one industrial backbone — production data finally flows where teams need it, in real time.
Production support applications
A suite tailored to daily manufacturing operations:
- production monitoring and machine status tracking,
- maintenance management and downtime analysis,
- quality control support and operator dashboards,
- reporting, workflow automation, and internal portals,
- logistics and process coordination tools.
Applications integrate with ERP, MES, warehouse, and enterprise systems.
Key innovations
Real-time industrial data
Large volumes of telemetry synchronized in real time across distributed plant infrastructure.
Edge intelligence & reliability
Local buffering, retries, exponential backoff, and offline recovery — continuity even during network or SCADA outages.
Modular & scalable infrastructure
Containerized microservices for flexible deployment:
- on-premise and industrial edge,
- private cloud and hybrid industrial-cloud setups.
Multi-system integration
ERP, MES, energy management, IoT, AI analytics, and external APIs.
Predictive capabilities
Combined historian data and analytics for predictive maintenance, anomaly detection, production optimization, and energy efficiency.
Client cooperation process
- Industrial process analysis — production environment, workflows, and integration needs.
- Architecture & integration design — SCADA, concentrators, historian, and ops apps.
- Development & customization — dashboards, industrial logic, workflows, and APIs.
- Infrastructure deployment — redundancy, monitoring, and security on plant or cloud.
- Testing & validation — signal verification, stress tests, and production checks.
- Launch & training — operators, engineers, and administrators.
- Continuous support — optimization, AI modules, and long-term evolution.
Vision
We connect production, energy, automation, and operational intelligence into one industrial backbone — efficiency, reliability, and data-driven decisions for Industry 4.0.