Smart SCADA Telemetry & IoT Gateway Integration
Client: Apex Manufacturing Group · Segment: Industry 4.0 · Published 2026-08-01
The Challenge
Apex Group operated 120+ legacy Siemens PLC controller units across multiple locations. Temperature, vibration, and motor-cycle telemetry was isolated inside regional field cabinets and regularly overwritten due to physical register limits, with no central status panel — leading to turbine wear and downtime outages.
The Solution
We engineered an IoT Edge Translator layer, connecting digital/analog signals to physical edge gateways running containerized Python parsers. Gateways convert PLC registers, compress parameters, buffer data locally during cellular dropouts, and stream metrics via TLS-encrypted MQTT tunnels to a cloud InfluxDB instance and a real-time React SCADA dashboard.
The Outcomes
- Buffer Protection: Edge store-and-forward buffers saved telemetry data during active network dropouts
- Predictive Alerts: Temperature trend alerts decreased breakdowns by 34%
- WebSocket Dashboard: Render latency dropped from 12s to 800ms