Case Study: Werner & Mertz modernizes process control with ProLeiT Plant iT

Migration and modernisation of a process control system during ongoing operation at Werner & Mertz

Werner & Mertz, a manufacturer of cleaning products, faced the challenge of modernizing its aging process control system without interrupting ongoing production. Their existing system had led to semi-automated areas requiring manual operation and faced increasing difficulty in sourcing spare parts. They enlisted the vendor ProLeiT to implement a solution using the Plant iT process control system to achieve a flexible, cost-effective, and fully integrated automation platform.

ProLeiT implemented a step-by-step migration strategy over six months, using an intelligent connector concept that allowed the old system and the new Plant iT V8 system to run in parallel. This approach enabled Werner & Mertz to transfer control of sub-segments incrementally without changing any process wiring, ensuring no production downtime and providing a safe rollback option. The results included the elimination of manual controls, significantly shortened process times, improved productivity and process reliability, and the establishment of an integrated system with MES functionality for conclusive reporting.

Werner & Mertz