IIoT & Industrial Automation Manufacturing, Automotive Assembly & Food Processing Plants 17 views

SCADA Monitoring System & IIoT Platform

Real-time multi-line industrial speed monitoring, trolley counting, instant Telegram alerts, and Google Sheets cloud archival.

Uptime Visibility 99.98%
Alert Dispatch Latency < 500 ms
Counting Accuracy 99.9%
Multi-Line Support Up to 32 Lines / Gateway

Live Multi-Line SCADA Telemetry Engine

Simulated Real-Time Sensor Broadcast (Modbus RS-485 / MQTT Gateway)

⚡ Latency: 18ms • Sync: OK
LINE 01 • MAIN CONVEYOR RUNNING
42.8 m/min
Trolley Count: 1,438
LINE 02 • ASSEMBLY RUNNING
38.4 m/min
Trolley Count: 1,192
LINE 03 • PACKAGING IDLE / CHG
0.0 m/min
Trolley Count: 840
💡 Interactive Demo: Adjust simulated line speed to see automated Telegram threshold alarms trigger.
42.0 m/min

Telegram Alert Bot

Automated Instant Dispatch
Bot Active
SPEED ALERT: Line 02
Conveyor operating below threshold: 14.5 m/m
Sent to: Plant Supervisors Group • 21:14:02
HOURLY SHIFT REPORT
Total Trolley Count: Line 01 (240), Line 02 (195)
Target Achievement: 92.4% • Auto Dispatched

Instant Telegram Bot integration eliminates downtime delays, alerting shift engineers within 500ms of any threshold deviation.

Google Sheets Cloud Sync

24/7 Global Access & Cloud Archival
Auto Push
Timestamp Line Speed Count
21:28:50 Line 01 42.8 m/m 1,438
21:28:50 Line 02 38.4 m/m 1,192
Dual Archival Architecture: Production logs are synced live into Google Sheets for quick mobile access and stored in dedicated SQL databases for monthly/yearly compliance.

Complete Technical Architecture & Specifications

Enterprise Industrial IoT (IIoT) & Web SCADA Solution

In modern manufacturing, unexpected line slowdowns, unrecorded conveyor stoppages, and disconnected data silos result in severe throughput losses. The ZerixTech SCADA Monitoring System solves this with an end-to-end, edge-to-cloud telemetry infrastructure that monitors speeds, counts production units/trolleys in real-time, instantly triggers Telegram notifications, and synchronizes live data into accessible Google Sheets alongside robust monthly/yearly archival databases.

01

Line-Wise Speed & Status Telemetry

Connects directly to plant optical encoders, proximity sensors, and PLCs (Siemens, Delta, Mitsubishi, Allen-Bradley) over Modbus RS-485 / MQTT. Continuously computes precise line speed (meters/min, RPM) and tags current line status (Running, Idle, Warning, Stoppage) with sub-second accuracy.

Sub-second telemetry sampling
02

Accurate Trolley & Unit Counting

Advanced software debounce filtering prevents duplicate counting and accounts for back-and-forth conveyor jitter. Delivers 99.9% counting precision for trolleys, trays, cartons, or finished parts across all shifts.

99.9% Debounced Precision
03

Real-Time Telegram Alerts & Bot

Plant managers and supervisors do not need to sit in front of a terminal all day. The built-in Telegram Bot dispatches instantaneous alerts for speed deviations, line bottlenecks, shift milestones, and hourly throughput digests straight to designated Telegram channels or private supervisor chats.

< 500ms Notification Latency
04

Google Sheets Sync & Dual Archival

Automatic continuous real-time sync with Google Sheets enables plant owners and stakeholders to view live production data on mobile phones anytime, anywhere without complex VPNs. In parallel, a separate monthly and yearly partitioned database preserves high-frequency historical telemetry for ISO audits and root-cause analysis.

24/7 Mobile Cloud Access
Plant Customization

100% Fully Customizable For Any Industrial Facility

Every manufacturing facility has unique conveyor designs, shift schedules, target quotas, and sensor placements. ZerixTech tailors the entire hardware-software stack:

✔ Custom PLC & Sensor Calibration
✔ Flexible Shift Schedules (2-Shift, 3-Shift, 24x7)
✔ Custom Speed Thresholds & Delay Timers
✔ Tailored Telegram Alert Thresholds & Group Routing
✔ On-Premise + Cloud Hybrid Deployment
✔ Local Offline Storage During Network Downtimes

Core System Capabilities

✓ Real-time Multi-Line Speed Tracking (m/min, RPM, cycle times)
✓ High-accuracy Trolley & Unit Counting with optical/inductive sensor integration
✓ Instant Telegram Bot Notifications for line alerts, breakdowns, and hourly production updates
✓ Beautiful, Organized Live Web SCADA Dashboard with line-wise status (Running, Idle, Maintenance)
✓ Live Google Sheets Cloud Sync for 24/7 anytime data access without complex IT setup
✓ Dual Monthly & Yearly Separate Archival Database System for audits and analytics
✓ 100% Fully Customizable Industrial Architecture tailored to plant-specific PLCs and workflows
✓ Local Edge Gateway Offline Buffering to ensure zero data loss during network downtimes
✓ Role-based Plant Supervisor & Management Access with live KPIs and OEE tracking
✓ Multi-protocol Support: Modbus RS-485 / TCP, MQTT, OPC-UA, and REST APIs

System Screenshots & Telemetry Views

SCADA Screenshot 1
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SCADA Screenshot 2
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SCADA Screenshot 3
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SCADA Screenshot 4
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Full Industrial Hardware & Protocol Support

Engineered to integrate seamlessly with existing plant machinery

Industrial Protocols Modbus RTU (RS-485), Modbus TCP, MQTT Sparkplug B, OPC-UA, Ethernet/IP, REST
PLC Brands Supported Siemens S7, Delta, Mitsubishi, Allen-Bradley, Schneider, Omron, Custom Microcontrollers
Plant Environments Conveyors, Bottling, Packaging Lines, Automotive Assembly, Textile Mills, Chemical

Project Overview

Category IIoT & Industrial Automation
Client / Industry Manufacturing, Automotive Assembly & Food Processing Plants
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