CABLES & WIRES • BROWNFIELD MODERNIZATION

From 350 to 650 Tons: Doubling Output Without New Machines.

A leading Egyptian cable manufacturer transformed its 20-year-old extrusion lines into a fully data-driven production environment, unlocking 85% more production capacity in just 4 months.

+85%
Production Increase
4 Months
Time-to-Value
ZERO
New Machines
-40%
Scrap Reduction

A Factory Running Blind

Despite strong market demand, this manufacturer was constrained at a production ceiling of 350 tons per month. Critical production data was locked inside 20+ year-old legacy PLCs and fragmented SCADA systems—turning daily operations into a “black box.”

  • Zero Real-Time Visibility

    No live monitoring of extrusion speed, tension, or die pressure across the production lines.

  • Manual Reporting Chaos

    Handwritten logbooks made it impossible to trace bottlenecks or stabilize cycle times.

  • Reactive Maintenance

    Motors and pullers degraded silently until sudden, costly line stoppages occurred.

ERROR_LOG.TXT
PRODUCTION LOG - LINE 2 MANUAL ENTRY

"09:00 - Started extrusion. Speed approx 40m/min."

"11:30 - Stopped. Motor hot. Waiting for maintenance."

"14:00 - Restarted. Scrap generated due to uneven cooling."

[ SYSTEM NOTE: DATA UNAVAILABLE FOR SHIFT ANALYSIS ]

THE SOLUTION

Non-Invasive Industrial Intelligence

Connecting Legacy PLCs

Integrated analog sensors and legacy PLCs without stopping production. Normalized fragmented data points (speed, torque, temperature) into a unified model.

// Device Integration

Real-Time Control

Replaced manual logs with live dashboards tracking cycle time stability and wire diameter deviation. Decision-making shifted to real-time.

// Real-time Analytics

Bottleneck Detection

Automatically detected hidden constraints, such as synchronization delays between pullers and cutters, enabling immediate correction.

// Quality Control

Before vs. After Niotek

Metric Before Niotek After Niotek Impact
Monthly Production 350 tons 650 tons +85% Increase
Material Scrap Baseline 40% Reduction Less Waste
Cycle Stability Variable Stable Higher Consistency
OEE Limited Audit-ready Actionable Insight
// Technical Specifications

Technical Spotlight

Legacy Integration

Seamless ingestion from 20-year-old industrial controllers without production downtime.

High-Frequency Analytics

Real-time monitoring of extrusion parameters (temp, tension) enables immediate detection of micro-stoppages.

Future-Ready Architecture

Prepared for Digital Twin simulation and predictive maintenance expansion without re-architecting.

CTA_PROMPT.SYS
"WE DIDN'T NEED NEW MACHINES. WE JUST NEEDED TO LISTEN TO THEM."

Unlock Your Factory’s Hidden Capacity.

Nearly double your output through software and process intelligence alone.