From Manual to Measurable - Modernizing Batch Production

The Problem

A leading manufacturer in the paints and coatings industry was facing limitations from manual and outdated production processes across two critical areas of its plant.

First, employees performed barrel-filling operations by hand, creating inefficiencies, safety risks and limited visibility into production flow. While a new semi-automated filler system had been purchased, it required integration into existing plant infrastructure to deliver value.

Second, the facility relied on aging, manual small-batch mixers that lacked standardization, modern safety features and centralized control. Operators had minimal visibility into mixer status, performance and historical data, making it difficult to optimize production or troubleshoot issues.

Across both areas, the absence of structured data and real-time insight limited the company’s ability to make informed operational decisions.

The absence of structured data and real-time insight limited the company’s ability to make informed operational decisions.

The Solution

GrayMatter’s Automation & Controls team partnered with the manufacturer to modernize and integrate both systems into a unified, data-driven operational environment, and incorporated a batch ID system that allowed operators to keep track of the batch production process.

For the semi-automated filler system, GrayMatter:

Designed the electrical architecture, including a remote I/O rack
Integrated the new filler with existing plant systems
Programmed PLC logic and communication interlocks to ensure safe, coordinated operation
Developed SCADA screens for real-time operator visibility, including valve status, fill monitoring and batch tracking

For the small batch mixer upgrade, GrayMatter:

Built a custom electrical enclosure to support new equipment
Programmed a PLC to control new mixers from a centralized system
Developed SCADA screens for mixer status, batch loading and alarm monitoring
Enabled historical data tracking and trending for improved analysis and performance optimization

Both projects were integrated into the plant’s SCADA platform, creating a consistent interface for operators and a scalable foundation for future digital initiatives.

Big Wins

The modernization effort delivered immediate improvements across operations:

Increased Safety

through standardized equipment and automated controls

Higher Levels of Automation

reducing reliance on manual processes

Improved product output

and production efficiency

Enhanced Batch Tracking

with structured, digital data capture

Greater Operator Visibility

into system status, alarms, and performance trends

Both projects were integrated into the plant’s SCADA platform, creating a consistent interface for operators and a scalable foundation for future digital initiatives.

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