Improving Real-Time Visibility and Operational Response for a Metal Filtration Technology Leader
SELEE, a leader in molten metal filtration, needed its newly commissioned kiln brought into the existing system with consistent visuals, alarms and reliable data. ITHENA used Ignition to onboard the kiln and build operator-centric screens and alarm workflows.
- Client
- SELEE, metal filtration technology leader
- Industry
- Metals and ceramics
- Solution
- ITHENA with Ignition
- Scope
- Kiln onboarding, operator visualisation, PLC and database integration, alarm management
- Headline result
- 32% faster operational response
Three numbers the kilns moved.
Results after ITHENA brought old and new kilns onto one Ignition system.
Improvement in output efficiency
Consistent screens across kilns improved output efficiency.
Faster operational response time
Alarm management and drill-down workflows sped up response.
Reduction in operator error
Intuitive operator interfaces cut mistakes.
Meet the organization and understand the context behind the transformation.
SELEE is a global leader in metal filtration technology, pioneering the use of ceramic foam and driving innovation in filtration, melt treatment, and transfer processes for all types of molten metals. Facing challenges in real-time Kiln monitoring, inconsistent visualization and workflows across old and new Kilns, and risks of data inconsistencies from PLC and database integration gaps, the client partnered with ITHENA. The outcome was seamless Kiln onboarding, operator-centric visualization, reliable data integration, and structured alarm workflows, delivering enhanced real-time visibility, standardized operations, faster issue detection, and improved operational efficiency, reducing errors and boosting overall plant performance.
Consistency across our legacy and next‑generation kiln assets was essential to scaling efficiently. ITHENA delivered exactly that. Their expertise helped us seamlessly unify our SCADA experience within Ignition, transforming a patchwork of old and new systems into a single, intuitive interface. By standardizing visualization and alarm workflows, our operators now work faster and with greater confidence—driving measurable gains in output without disrupting production. It’s been a true accelerator for our digital transformation
Shawn Hawkins, Automation Controls Systems Specialist, SELEE
Old and new kilns that behaved differently.
The new kiln had no live visibility, and visuals, alarms and data differed between old and new kilns.
- Lack of real-time visibility for the newly commissioned Kiln within the existing system
- Inconsistent visualization, alarms, and workflows across old and new Kilns
- Risk of data inconsistency from PLC tag mapping and database integration gaps
- Lack of intuitive operator interfaces, slowing issue detection and resolution
How ITHENA closed the gaps.
ITHENA, in partnership with Ignition, empowered the client with:
Seamless Kiln Onboarding
Integrated new Kiln into the existing Ignition V8.1.12 environment with minimal disruption to live plant operations
Operator-Centric Visualization
Designed and deployed intuitive operator screens using the Ignition Vision Module, including Kiln Overview, Zone Analysis, Trending, and Alarm dashboards for real-time and zone-level visibility
Reliable Data Integration
Established direct PLC tag connectivity and MS-SQL database integration to enable accurate real-time and historical data capture across Kiln operations
Alarm Management & Drill-Down Workflows
Configured intelligent alarms and structured drill-down navigation to accelerate identification of abnormal conditions and support faster operational response