insights

Learn how best-in-class companies stay competitive. With over 35 years of expertise to help clarify and create confidence, Polytron shares our Resources and Insights to help you better understand production issues or strategies to take your manufacturing to the next level.

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Webinar

Webinar: Value of Packaging Turnkey for CAPEX Projects

Damian Stahl, PE, PMP, and Scott Richards, PE, PMP dive deeper into the value of Packaging Turnkey Solutions for CAPEX…

Webinar

Turnkey Solution – Project Management

Polytron offers Turnkey Solutions to provide resources and experience in-house for the management of capital projects from start to finish.…

Brochure

Packaging Turnkey Solution

With over 30 years of packaging experience, Polytron has developed domain expertise in delivering packaging turnkey solutions to meet your…

Brochure

Industrial Network and Security Solutions (INSS) Overview

Developing a robust and secure network infrastructure requires protecting the integrity, availability, and confidentiality of control and information data. Polytron’s…

Brochure

Industrial Network and Security (INSS) Site Checklist

The Industrial Network and Security Solutions (INSS) Site Checklist is a tool created for technical or non-technical personnel to review…

Article

It’s Time to Step-Up Machine Safety

OEMs understand the need to comply with machine safety standards, but new requirements may necessitate bringing in a third party…

Webinar

Video Clip: Cybersecurity and Defense-In-Depth Strategy

(11 min 39 sec) Protecting industrial assets requires a “defense-in-depth” security approach that addresses internal and external security threats. This…

Case Study & Whitepaper

Drive Replacement for Long-Term Sustainability

A fortune 100 CPG manufacturer needed to find a solution to replace all drives in their distribution center that provides…

Webinar

Video Clip: Industrial Network and Cybersecurity Trends

(4 min 52 sec) - In today’s world, firewalls are a thing of the past. Networks are under constant attack…

Brochure

Smart Manufacturing Solutions for the Factory of the Future

As experts at leveraging Industry 4.0 solutions and best practices to optimize manufacturing systems, Polytron will evaluate client’s specific technology…

Brochure

Inventory Management

Maintain control of inventory to increase production efficiency and reduce working capital requirements: A real-time Inventory Management software system can…

Brochure

Visual Workflow

Manufacturers struggle to gain visibility into their latest processes to address quality, downtime, compliance, maintenance, and all other functions required…

Brochure

Traceability

Traceability in production is critical to protecting consumers and your brand: For regulated plants, recording, tracking, and tracing the genealogy…

Brochure

Quality Management

High quality made efficient, sustainable, and repeatable: The availability of real-time, contextualized information using a Manufacturing Operations Management (MOM) platform…

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Production Management

Manufacturing operations have many inherent complexities: Production Management with a Manufacturing Operations Management (MOM) platform will address complexities so you…

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Maintenance Management

Manage equipment reliability and longevity by being proactive: Manufacturing Operations Management (MOM) platforms provide insight into production processes, equipment performance,…

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Performance Management

What is limiting your factory performance? Built on a Manufacturing Operations Management (MOM) platform, the Performance Management solution framework benchmarks…

Brochure

Energy Management

Optimize operation while spending less on utilities: Staying competitive in today’s manufacturing landscape demands running operations as efficiently as possible…

Article

Rockwell Journal, Food and Beverage Edition: How Food Manufacturer Integrated 5 Lines During Building Construction, Aggressive Timeline

On April 16, 2021, Rockwell Automation featured, “How Food Manufacturer Integrated 5 Lines During Building Construction, Aggressive Timeline,” in the…

Webinar

Panel Discussion Series: Manufacturing Trends and Accelerated Technology

We are pleased to bring you insights from several of our experts on current manufacturing trends and how this past…

Webinar

Video Clip: Traceability – Track and Trace

A video clip (5 min 16 sec) from The Smart Manufacturing Journey webinar describing an a case study called: Track…

Webinar

Video Clip: Silo Monitoring

A video clip (6 min 53 sec) from The Smart Manufacturing Journey webinar a case study, Silo Monitoring.

Webinar

Video Clip: Modern MoM Platform Increases OEE

A video clip (7 min 26 sec) from The Smart Manufacturing Journey webinar a case study, Modern MOM Platform Increases…

Webinar

Video Clip: Inventory Management Using RFID

A video clip (6 min 08 sec) from The Smart Manufacturing Journey webinar a case study, Inventory Management Using RFID.

Webinar

Video Clip: Choosing Your MOM Platform

A video clip (2 min 47 sec) from The Smart Manufacturing Journey webinar describing what to look for in your…

Webinar

Video Clip: Overview of Smart Manufacturing

A video clip (7 min 53 sec) from The Smart Manufacturing Journey webinar describing an overview of Smart Manufacturing.

Webinar

Webinar: The Smart Manufacturing Journey – Best Practices, Successes, and Lessons Learned

Many manufacturers are well underway with their Smart Manufacturing transformation and are seeing the business results of reduced costs, higher…

Webinar

Webinar: Network as a Differentiator in Manufacturing

Use your network as a competitive advantage in terms of business process and optimization. Real time decisions need to be…

Webinar

Webinar: Simulation + Emulation

When evaluating potential system design options or validating automation system design functionality, choosing the right software tool and approach can…

Webinar

Webinar: Improve Product Tracking and Inventory

To minimize downtime, a plan was put in place to upgrade the manufacturer’s tracking system. MOM software that interfaced with…

Webinar

Webinar: Sipping On Success

In the process of considering a costly capital expenditure, the team at Milo’s Tea asked a question which changed everything:…

Case Study & Whitepaper

Updating Aging Assets to Meet Market Demand

Downtime, reduced productivity, and poor product quality raised the risk that a food and consumer goods packaging manufacturer could not…

Case Study & Whitepaper

RFID and MOM Traceability Solution

Current inventory procedures at an industrial filtration membrane manufacturing plant were expensive and inefficient causing excessive downtime. To minimize downtime,…

Case Study & Whitepaper

Reduce Risk: Cybersecurity

With rising threats of cyber-attacks and security breaches, there is an urgency within companies to protect their virtual borders by…

Case Study & Whitepaper

New Network Standard

A multinational manufacturing plant unexpectedly shut down causing production to cease, staff to stand by idle, and product to slowly…

Case Study & Whitepaper

Near Vertical Startup During International Relocation

A manufacturer needed to relocate internationally, move its lines to an existing facility without interrupting operations, and consolidate and optimize…

Case Study & Whitepaper

More Production with Less Capital

Inefficient bottling lines and aging line assets appeared to be creating downtime and waste for a beverage manufacturer. With operation…

Case Study & Whitepaper

In-Line Blending Effectively Manages Supply Cost

Volatile cooking oil prices were creating an unsustainable expense structure leading to the inability to maintain market share, loss of…

Case Study & Whitepaper

Food Manufacturer Integrates Five Lines

Consolidating and upgrading six lines from three different factories into a single facility was a challenging task for a food…

Case Study & Whitepaper

Aseptic Filling System Enables Expansion

For wider distribution, a multinational fruit-based beverage manufacturer needed to change the way it took their product to market with…

Case Study & Whitepaper

Expanding Packaging Capacity

When one of your largest retailers is asking for a packaging change to better meet consumer demand, you want to…

Case Study & Whitepaper

Safety Verification and Validation

New line requires quick commissioning and startup while ensuring company safety specifications are met with machines coming from multiple vendors.…

Case Study & Whitepaper

Upgrading Aging Network to Reduce Downtime and Increase Performance

  Upgrading the old network infrastructure would allow the company to maintain a competitive advantage and meet customer demands by…

Webinar

Video Clip – Polytron, Inc 2019 System Integrator of the Year – CEO Interview

Polytron Inc. is the 2019 System Integrator of the Year for the Mid-Sized System Integrator Category. CEO Ron Rich shares…

Case Study & Whitepaper

Process Control System Upgrade for Efficiency

A process control system update presents multiple challenges - especially when the system is over 25 years old with modifications…

Brochure

Polytron Smart Manufacturing Maturity Index

The Smart Manufacturing Maturity Index provides a guide to where you might be in your Smart Manufacturing journey.  A best…

Brochure

Polytron Manufacturing Consolidation Offering

When your company’s manufacturing strategy calls for the consolidation of manufacturing facilities,  you want a System Integrator who knows how…

Brochure

Smart Manufacturing Full System Brochure

Many manufacturers are overwhelmed with the amount of effort, level of detail, or expertise required to successfully complete capital projects…

Case Study & Whitepaper

Digital Twin Gives Clarity to Bottling Line Issues and Doubles OEE Output

A comprehensive line audit and an exact 3-D simulation model of the production line created clarity about issues and showed…

Case Study & Whitepaper

Sipping on Success – Deploying Smart Manufacturing to Improve Productivity

Co-authored with Parsec Corporation - In the process of considering a costly capital expenditure, the team at Milo's Tea asked…

Case Study & Whitepaper

Batch Management Replacement Yields High Returns

A global snack baker eliminated quality losses and downtime, and increased yield by 30% after replacing their batch management and…

Brochure

Polytron Life Sciences Offering

Polytron is uniquely positioned and fully qualified with certified best-in-class systems integration talent and industry expertise to deliver the special…

Brochure

Polytron Consumer Goods Offering

Polytron is uniquely positioned and fully qualified with certified best-in-class systems integration talent and industry expertise to deliver the special…

Brochure

Polytron Automotive Offering Brochure

Polytron is your one-stop provider - whether you’re in need of strategy, systems, automation, equipment, processes, or training for manufacturing.…

Brochure

Polytron Chemical Offering Brochure

Polytron is uniquely positioned and fully qualified with certified best-in-class systems integration talent and industry expertise. This enables us to…

Case Study & Whitepaper

Smart Manufacturing Maturity Checklist

Smart Manufacturing (Industry 4.0/Manufacturing 4.0) is the use of real-time data and technology when, where and in the forms that…

Brochure

Polytron Food and Beverage – Full Manufacturing Systems and Solutions

Polytron, Inc. is a CSIA-Certified Full Manufacturing Systems and Solutions Integrator and 2019 System Integrator of the Year.  Applying 35…

Article

Polytron – Leadership Longevity

  Gwinnett Business Journal, May 2013 - Ask Polytron President [and Founder] Charlie Jager about his business and he'll tell…

Case Study & Whitepaper

Emulation: Lower Risk with a Digital Twin

While there is no crystal ball to predict the outcome of a project, there is proven technology that delivers valuable…

Case Study & Whitepaper

Track and Trace Keeps Consumers Safe and Healthy

Manufacturing a product with a time-sensitive shelf life involves abiding by data requirements to ensure consumer health and safety guidelines.…

Article

How Manufacturer Upgraded its Network

2016 - The company replaced its aging cabling with an industrial network that improved plant-to-business data collection and reporting and…

Case Study & Whitepaper

Control System Modernization

A Major beverage company has a high number of obsolete Variable Frequency Drives (VFDs) causing disruptive downtime throughout multiple plants.…

Brochure

eBook: Smart Manufacturing: Beginning the Journey

  Manufacturers’ success over the coming years will be comprised of connected, data-driven processes that combine innovative automation, interactive connectivity,…

2015 System Integrator of the Year, President’s Interview

Polytron, Inc. has been named 2015 System Integrator of the Year by CFE Media.  View the interview with Charlie Jager,…

Webinar

Roadmap to Hardware and Software Migration

The goal of obsolescence planning is to accurately quantify risks in order to determine if mitigation or elimination will make…

Brochure

Polytron Safety Services and Solutions

 Applying years of machinery safety engineering expertise in manufacturing, we help your company reach its safety program goals by meeting you where you…

Case Study & Whitepaper

FAT Survival Guide

If this is your first Factory Acceptance Test (FAT), you’re probably wondering what to expect.  What will happen at the…

Article

Standardized Historian Software Boosts Quality for Automotive Supplier

December 2014, The Rockwell Journal, Manufacturing Intelligence solution enables brake manufacturer to meet quality control and reporting objectives while offering…

Webinar

Obsolescence – Operating on Borrowed Time

Hear a discussion of the state of aging automation assets within the manufacturing environment and its impact as more and…

Case Study & Whitepaper

Driving Quality with Manufacturing Intelligence

An automotive component manufacturer was having challenges maintaining, troubleshooting, and upgrading their legacy quality control and parts tracking system. A…

Case Study & Whitepaper

Restoring Production Performance

The existing network was over 15 years old with an aging infrastructure of wiring and Ethernet. Although, new data requirements for…

Case Study & Whitepaper

Job Hazard Checklist

Safe working conditions continue to rank in OSHA's Top 10 violations for manufacturing.  Taking a proactive step to evaluate your…

Case Study & Whitepaper

Juicing Up HMI Performance with ACP Thinmanager

Polytron jumped in to help a major juice processor and bottler resolve hardware and software issues with approximately 100 Human Machine…

Article

New Approaches to Asset Management Yield Big Energy Savings

2014 - Intelligent use of control systems can maximize the energy efficiency of industrial equipment by, among other things, making…

Article

Rockwell Automation Machinery Safety Solution Partner

April 2014 - Polytron, Inc. becomes North America’s first designated Rockwell Automation Machinery Safety Solutions Partner. This new Machinery Safety…

Case Study & Whitepaper

Machine Safety Checklist

Machine safety continues to rank in OSHA's Top 10 violations for manufacturing.  Taking a proactive step to evaluate your current…

Article

How Do You Balance Connectivity with Security on the Plant Floor?

Guest Blog on ISA Interchange - February 5, 2014 - Manufacturing facilities increasingly are becoming reliant on network connectivity to…

Article

Standardizing Control Room HMIs

Control Engineering - 12/23/2013 by Chris Parkinson.  Next Generation HMIs create an environment where operators and technicians can move at…

Article

Four Key Benefits of Integrated Safety Control Networks

November/December 2013 - InTech Channel Chat - By Jay Cross, CAP There has always been some form of safety systems…

Case Study & Whitepaper

Leveraging Critical Data to Drive Manufacturing Decisions

Manufacturing Intelligence (MI) projects are initiated to improve manufacturing operations by turning data into actionable information that drives business results. The latest…

Article

Make Sense of Complex Machine Safety Upgrades

TheJournal, October 2013 by Sean Daswani, PE, Polytron Machine Safety Lead - Discover how an industrial firm and its system…

Webinar

Job Safety Analysis – CBLO Sample

A Computer-Based Learning Object (CBLO) provides online training on topics that are standardized and repetitive in content.  This Job Safety…

Article

EPA Fines Avoided with Highly Reliable Emissions Data System

July 23, 2013 - A leading manufacturer of ceramic proppant for the oil and gas industry was seeking an emission…

Webinar

Share and Share Alike Webinar

Learn how to leverage the power of automated workflow to increase visibility and access critical manufacturing documents and operations data…

Brochure

Polytron, Inc. e-Brochure

  Polytron, Inc., is a CSIA-Certified leader in engineering consulting and systems integration, 2019 System Integrator of the Year, and…

Article

Create a Safe Environment

March 2013 - Manufacturing Business Technology Insert (Jon Minnick, Associate Editor) - If you want your safety program to go…

Article

The Virtual Plant Seen Through Standardized 3D HMI

As the manufacturing industry moves rapidly into the virtual, paperless era, the standardized working environment for managing manufacturing operations require…

Webinar

CBLO – Labeler Changeover

Computer Based Learning Objects (CBLOs) can deliver employee how-to instruction at the action point of the work. In this example,…

Article

Turning Data into Information with Manufacturing Intelligence

Manufacturing intelligence systems offer manufacturers access to key performance indicators for increased troubleshooting, product tracking, and downtime management.  However, implementation…

Webinar

Computer Based Learning Objects – Polytron Training Certification Process Flow

Computer Based Learning Objects or CBLOs allow employees to view training processes anytime, anyplace. This CBLO provides an overview of…

Article

Motion Control Product Handling, Re-feeder Challenges

Controlling the product flow in adjacent machines can be challenging.  Polytron and Finesse Manufacturing address product handling and re-feeder interruptions,…

Article

Tribal Knowledge in Quality Magazine

A manufacturing plant may have formed three different tribes: each with its own language, customs and traditions. This can lead…

Case Study & Whitepaper

Machine Safety Goals Achieved

After assessing risks, machines were upgraded to include new safety features, and operators were trained to ensure the safety upgrades…

Webinar

The Emulation Equation Webinar

By using The Emulation Equation to test your new controls system off site, you can get your new line up and…

Webinar

Train on the Fast Track Presentation

Your best experts are on the factory floor - but are they your best instructors?  They can be if you…

Webinar

The New Knowledge Engine Webinar

Keeping your employees up to speed on the latest technologies, processes and skills is not easy - especially in a…

Article

Cracking the Code Rockwell Journal

Standardization could make everything run smoother, but it can be costly and include risks of its own.  What do you…

Webinar

Cracking the Code Webinar

Watch this new webinar highlighting a case study with one of the world's largest consumer goods manufacturers. A newly standardized…

Case Study & Whitepaper

Aging Workforce Drives Onboarding and Technology Transfer Push

As Baby Boomers retire, companies stand to lose vast amounts of knowledge and experience.  Employees with years on the job…

Podcast

CSIA Solutions Forum: People Readiness Improves MI Project Success

How do you guarantee a successful Manufacturing Intelligence project and realize targeted results for measurable ROI on MI projects?  One…

Podcast

CSIA Solutions Forum: Intelligence and Continuity – Automating Paper Workflow

Hear how one global food manufacturer embraced the move from paper-based operations workflow processes to automated workflow management and data…

Webinar

Subject Matter Experts Can Be Training Experts

Only 13% of those surveyed consider their own Subject Matter Experts as their best instructors. Your best instructors can be…

Webinar

Operator Driven Reliability

A majority of asset related production losses result from poor operational practices and not poor maintenance practices as commonly thought.…

Article, Case Study & Whitepaper

Vertical Startup Ensures National Beverage Rollout Gets to Market Sooner

A global beverage manufacturer needed to increase production capacity to expand a new product nationally, but developing the processes requires…

Case Study & Whitepaper

Streamlined Workflows

The ability to collaborate, share information and manage content from plant floor to the C-suite may already be available if…

Case Study & Whitepaper

Speed Up Packer

A straightforward request: increase line throughput by 20-25%. The Case Packer has been suspect as being the issue for line's…

Case Study & Whitepaper

Rebuild An Old Line

Time is tight, equipment dated and space is limited.  Overall Equipment Efficiency (OEE) will need to increase significantly, increasing throughput…

Case Study & Whitepaper

A Different Oil Business

Their world runs on oil; vegetable, sunflower, corn and soybean.  The challenge: Manage the fluctuating commodities cost, maintain recipe quality control and…

Case Study & Whitepaper

The New Knowledge Engine

Making Computer Based Learning Objects an integral part of your Train-the-Trainer program can improve on-the-job performance and reduce training time…

Case Study & Whitepaper

Digital Twin Allows Rapid ESL Commissioning

Emulation is an absolute game changer when it comes to integrating new process and  packaging lines. It allows you to…

Case Study & Whitepaper

Go (Recon)figure

The company was already experiencing pain by sending manufacturing out to co-packers.  To increase flexibility and capacity demanded the old…

Case Study & Whitepaper

Training Program Engages Staff

What happens when a seasoned employee base of Supervisory Leads and Palletizer Operators are down 15% from the target shift…

Case Study & Whitepaper

Tribal Knowledge

In manufacturing, repeatable, measurable process is prized and winging it is verboten. Yet, informal solutions developed by plant personnel can…

Case Study & Whitepaper

Train on the Fast Track White Paper

Your best instructors can be subject matter experts from within your own organization.  The key is to tailor your instructor…

Case Study & Whitepaper

Run Line 24×7?

For a large beverage company, demand equates to a 20% increase in production, or an additional one million cases per…

Case Study & Whitepaper

Jet Fighter Tactics for Training

Using Emulation to address training challenges of plant floor downtime and provides an avenue to demonstrate the functionality of major…

Case Study & Whitepaper

The Emulation Equation Case Study

The startup phase of a new manufacturing system can easily account for one-half the expense of the project.  There is…

Case Study & Whitepaper

Using Data-Driven Decisions to Improve Operations White Paper

Manufacturing Intelligence (MI) projects are initiated to improve manufacturing operations by turning data into actionable information that drives business results.…

Case Study & Whitepaper

Cracking The Code

  You've got a complex system that represents millions of dollars in capital investment.  But, it's running slowly, creating bottlenecks…

Case Study & Whitepaper

Organizational Culture Change Through Instructor Certification Program (ICP)

The needs to establish an effective training program was driven by two known factors 1) the accepted culture of withholding…

Article

Helping Global Food Manufacturer Achieve the Perfect Blend

A global food manufacturer challenges Polytron to completely modify the method they use to blend oil in all of their…

Case Study & Whitepaper

Process System Cuts Hardware Cost

By Richard Phillips, PE, PMP - AB Journal, April 2010 - Reducing cost is always one of the top priorities…

Article

Plan, Plan, Plan

By Theresa Houck, Executive Editor, TheJournal, Oct 2007 - Sorting out the details of a control system implementation early in…

Article

Chart Your Progress

By Brent Stromwall, PE, PMP - The Journal, Oct 2006 - Measuring Overall Equipment Effectiveness can make the most of…

Article

Distributed Motor Control White Paper

The Journal, Oct 2004 - Distributed Motor Control improves installation.  Rockwell Automation Solution Partner, Polytron teamed with Rockwell Automation to…

Article

Rebuild Your Line

By Brent Stromwall, PE, PMP - TheJournal, Oct 2009 - Rebuilding a bottling line can seem like a daunting task,…

Article

Troubleshoot Packing Lines

By Brent Stromwall, PE, PMP - TheJournal, Nov 2005 - Use simulation to help adjust labeler without stopping line.

Article

Finding Solutions Together

By Ken Schnepf, Managing Editor, TheJournal, June 2008 - A global network of top system integrators is available at your…

Article

Distributed Motor Control in The Journal

By Brian Griffin, Rockwell Automation, June 2005 - Distributed Motor Control improves installation.  Rockwell Automation Solution Partner, Polytron teamed with…

Article

The Emulation Equation White Paper

The Emulation Equation - The startup phase of a new manufacturing system can easily account for one-half the expense of…

Article

Using Data-Driven Decisions to Improve Operations

By Richard Philllips, TheJournal, Dec 2010 - Many manufacturing intelligence systems fall short of meeting expectations providing manufacturers with reams…

Article

It’s All About Collaboration

The key to an integration project is using teamwork to define and attain project success. Identifying the technical solutions, meeting…

Article

Share and Share Alike in Automation World

The ability to collaborate, share information and manage content from plant floor to the C-suite may already be available if…

Article

Learn More About Emulation

You need to increase capacity, so you are adding a new line or rearrange your geographical footprint to lower distribution…

Article

Process System Cuts Hardware Cost by 25% in Rockwell Automation Journal

Reducing cost is always one of the top priorities for every automation integration project. Combine this with the economic downturn…

Case Study & Whitepaper

Starving Packer

Engineers at a large consumer packaging company believe they have a problematic code problem with a laner.  Polytron applies emulation…