Azure
Case Study

Real-Time IoT Dashboard on Azure for Beverage Manufacturing

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A leading beverage manufacturer operating multiple high-speed production lines needed a real-time digital operations dashboard for monitoring filling lines, packaging machines, mixer units, and utility consumption. PROLIM developed an Azure-based real-time streaming and analytics platform, integrating machine telemetry with Siemens xHQ for operational intelligence. The solution provided instant KPI visibility, early fault detection, and a unified 360° overview of plant productivity and performance.

  • No real-time view of machine performance (fill levels, pressure, temperature, flow rates)
  • Legacy PLCs and SCADA systems had no unified data streaming mechanism
  • Delayed reporting impacted decision-making and root-cause analysis
  • Required millisecond-level data ingestion for high-speed cold drink lines
  • Need to integrate with existingSiemens xHQ dashboards
  • On-prem data silos needed to be brought to cloud securely

PROLIM implemented a real-time IoT streaming and analytics solution on Microsoft Azure, integrated seamlessly with Siemens xHQ:

  • Azure IoT Hubto securely connect bottling, packaging, and quality control machines
  • Azure Stream Analyticsto process real-time telemetry (temperature, carbonation, levels, flow, speed)
  • Azure Function Appsfor event-driven logic, threshold alerts, and data routing
  • Azure Database for PostgreSQLto store processed KPIs, production batches, shift logs, and trend data
  • Azure Data Lakefor long-term storage and advanced analysis
  • REST/OPC UA connectorsto send transformed data to Siemens xHQ real-time dashboards
  • Power BIfor plant managers to view KPI summaries, OEE trends, and downtime patterns
  • Azure AD + Key Vaultensuring secure access, token management, and compliance

  • Real-time line performance monitoring (filling speed, mixing accuracy, carbonation control)
  • Early detection of anomalies such as temperature deviations or flow inconsistencies
  • Faster decision-making with live dashboards in Siemens xHQ
  • Unified data hub across PLCs, SCADA, MES, and Lab systems
  • Improved quality compliance and reduced wastage
  • Scalable architecture to onboard additional production lines or plants

  • Instant visibility (sub-second latency)of production KPIs across all lines
  • 30% reductionin quality deviations by detecting anomalies early
  • 20% improvementin bottling and packaging line efficiency
  • 50% fasterescalation during breakdowns due to real-time alerts
  • Seamless integration withSiemens xHQ, enabling a complete operational view
  • Foundation built for predictive maintenance, energy analytics, and digital twin initiatives

The Azure IoT streaming platform empowered the manufacturer with real-time insights, higher efficiency, fewer quality issues, and a scalable cloud foundation for future digital transformation.

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