Manufacturing Visualization in the Construction Industry — Liapor
Liapor GmbH & Co. KG has been manufacturing lightweight expanded clay aggregates and related construction materials for more than 60 years. Their products combine strength, low weight, insulation properties, and long-term sustainability. As part of a production optimization effort, Liapor modernized its manufacturing processes in cooperation with mySCADA — cooperation since 2018, implementation completed in 2025.
Project Requirements
- Redundancy in the event of failures — without the need to stop production
- Visualization of the production process — production overviews, consumption monitoring
- Multi-user support — simultaneous monitoring by multiple employees
- Unlimited data logging
Project Scope and Size
The system is a multi-protocol solution enabling data collection and integration from diverse control systems across the entire production process:
- 24 Rockwell PLC systems (Micro, MicroLogix, SLC500, CompactLogix, ControlLogix)
- 1 Siemens SIMATIC ET200S PLC (certified control of a multi-fuel burner)
- Approx. 10,000 I/O signals throughout the production process
- Approx. 15,000 tags in the central HMI/SCADA system
Project Solution
Local visualization within production facilities is implemented using Rockwell PV800 and mySCADA myPANEL 10” touchscreen panels. The central visualization system runs myPRO on a Linux Debian server with approximately 15,000 tags.
The central HMI/SCADA system provides:
- Visualization of data from all production PLCs with unlimited historical data logging
- Alarms evaluated separately for individual production sections with role-based access
- Simultaneous real-time access for more than 20 users without affecting server performance
- Mobile access via VPN for field monitoring and control on tablets
- Advanced production reports and analyses
Visualization Highlights
The system includes production overviews for raw material processing, trend charts for main drives (rotary kiln and rotary cooler), graphical silo level monitoring with calculated tonnage and density, compressed air pressure monitoring across production stages, and a final inspection system using ultrasonic sensors with IO-Link communication for quality control of finished products.
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