Case Study: DiGeronimo Aggregates achieves $100,000+ in energy and maintenance savings, improved kiln control and EPA compliance with AVEVA (Wonderware)

Wonderware Software Brings Aggregate Plant Up to Date and Enhances Operations

DiGeronimo Aggregates, a 65‑acre aggregate plant in Independence, Ohio, faced the challenge of modernizing a 19th‑century facility: transitioning from oil/gas to coal, meeting strict EPA reporting, stabilizing kiln temperature for consistent product quality, and enabling scalable expansion despite outdated electrical systems and dispersed operations. DiGeronimo turned to AVEVA, deploying AVEVA’s Wonderware software suite (Industrial Application Server, InTouch HMI, ActiveFactory, Historian and Wonderware Industrial Tablets) to provide centralized SCADA/automation and mobile operator access.

AVEVA’s Wonderware solution centralized PLC and SCADA control, added wireless tablets for field control, and automated historian-based reporting and alarms, enabling proactive maintenance and remote monitoring. The result: operators gain at-a-glance plant visibility and fewer site trips, EPA reporting is automated, and planned maintenance has avoided costly kiln pre-heats (~$5,000 each) for total savings exceeding $100,000, while delivering improved product consistency and a standardized, scalable platform for future expansion.

DiGeronimo Aggregates

Andy Holtom

Manager of Electrical Engineering Services