A smart and connected production environment for Technoform

From isolated systems to a connected, data-driven production environment

Technoform is a global leader in customised polyamide solutions, with deep expertise in extrusion manufacturing. When setting up a new greenfield site, the company saw an opportunity to test how data and AI could improve its production processes.

The ambition was to move beyond isolated systems and create a connected production environment where data could flow across machines, systems and applications. This would give operators better real-time visibility, make historical production data easier to analyse and enable AI-assisted quality control.

The challenge was to integrate these technologies with the existing production infrastructure while making sure the solution remained flexible and could evolve with Technoform's needs.

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A connected foundation for smarter production

The project focused on four areas: creating a unified data foundation, improving real-time visibility, making historical data actionable and introducing AI-assisted quality control.

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A unified data foundation

Coretecs implemented a Unified Namespace (UNS) using HiveMQ as an MQTT broker, connecting machines and sensors across the production environment.

The UNS provides a central layer for production data, regardless of machine brand or communication protocol. Working closely with Technoform's process experts, Coretecs designed the architecture around their specific production processes.

This created a flexible foundation that supports current applications while making it easier to connect new technologies in the future.

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"When I saw Coretecs' architecture, I saw a reflection of my own vision for system integration. It was focused on flexibility, growth, and the future – exactly what we needed." - Leiv Hendrickx, IT Manager and Global Lead IT Architect, Technoform Northwest Europe

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Real-time production insights

To turn production data into something operators could act on, Coretecs implemented a modern SCADA platform using Ignition.

The platform provides operators with real-time visibility into production and was designed around their actual workflows. Rather than simply introducing a standard interface, Coretecs worked with Technoform's operators to make sure the solution fits their day-to-day needs.

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Making historical data actionable

Real-time data shows what is happening now. Historical data helps explain why.

With a Canary historian, Technoform can analyse production trends, identify recurring patterns and investigate the root causes of issues. This gives process experts the information they need to support continuous improvement and make decisions based on production data.

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AI-assisted quality control

The next step was bringing AI into the production process.

Coretecs developed a custom AI-powered quality control system using modular hardware and a custom model trained on Technoform's own production data. The system continuously monitors the production line and spots anomalies in real time.

Instead of relying solely on manual spot checks after production, operators can now identify potential quality issues while production is still running. This allows them to intervene earlier, reduce waste and learn from every defects.

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From pilot to scalable foundation

The greenfield site provided Technoform with a practical environment to test a new approach to digital manufacturing. The project delivered better access to production data, improved operational visibility and AI-assisted quality control.

Just as importantly, it created internal support for the approach and a foundation that can be extended to larger production lines and other sites.

The project shows how connectivity, data and AI can work together to turn production data into actionable insights, while keeping the people operating the systems at the centre of the solution.

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