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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Smart Manufacturing Resources
What Can You Do NOW to Improve Performance? GOOD NEWS! There are many tools and resources that can provide manufacturers…
Article
Control Engineering, June 2022 Edition: Know What to Keep or Redesign in HMI Migrations
Control Engineering featured, "Know What to Keep or Redesign in HMI Migrations," in the June 2022 edition of The Control…
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Machine Safety Services
Applying years of machine safety engineering expertise in manufacturing, we help your company reach its safety program goals by meeting…
Article
Travis Holley Promoted to Machine Safety Services Manager at Polytron, Inc.
Duluth, GA – 10 May 2022 – Polytron, Inc., a leading consulting and engineering firm serving manufacturers in North America,…
Article
Polytron Meets CSIA Requirements for FOURTH Time!
April 13, 2022 (Duluth, GA) – As the founding auditing firm that has performed the most CSIA audits around the world,…
Article
Rockwell Journal, January 2022 Edition: How a Fortune 100 CPG Firm Replaced 270 VSDs
Rockwell Automation featured, “How a Fortune 100 CPG Firm Replaced 270 VSDs,” in the January 2022 edition of the Rockwell…
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Process Turnkey Solutions
Today’s market demands flexibility for consumer-driven products with high yield, sustainable OEE, ease of operation, expanded and updated batch capabilities.…
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Manufacturing Consolidation
When your company’s manufacturing strategy calls for the consolidation of manufacturing facilities, you want a System Integrator who knows how…
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Safety Turnkey Solutions
Polytron is a CSIA-Certified leader in engineering consulting and systems integration and is 2019 System Integrator of the Year. You…
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Life Science Manufacturing Solutions
Polytron is a CSIA-Certified leader in engineering consulting and systems integration and is 2019 System Integrator of the Year. Applying…
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Full Manufacturing Systems and Solutions – 40 Years
40 Years of delivering Polytron’s expertise in full manufacturing systems and solutions meet holistic manufacturing needs across the plant floor…
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Food and Beverage Manufacturing Solutions
Polytron is a CSIA-Certified leader in engineering consulting and systems integration and is 2019 System Integrator of the Year. Applying…
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Consumer Packaged Goods Manufacturing Solutions
Polytron is a CSIA-Certified leader in engineering consulting and systems integration and is 2019 System Integrator of the Year. Applying…
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Chemical Manufacturing Solutions
Polytron is a CSIA-Certified leader in engineering consulting and systems integration and is 2019 System Integrator of the Year. Applying…
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Polytron Overview
Polytron’s expertise in full manufacturing systems and solutions meet holistic manufacturing needs across the plant floor – from raw materials…
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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…
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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.…
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Packaging Turnkey Solution
With almost 40 years of packaging experience, Polytron has developed domain expertise in delivering packaging turnkey solutions to meet your…
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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…
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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…
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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…
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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…
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Inventory Management
Maintain control of inventory to increase production efficiency and reduce working capital requirements: A real-time Inventory Management software system can…
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Visual Workflow
Manufacturers struggle to gain visibility into their latest processes to address quality, downtime, compliance, maintenance, and all other functions required…
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Traceability
Traceability in production is critical to protecting consumers and your brand: For regulated plants, recording, tracking, and tracing the genealogy…
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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…
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Energy Management
Optimize operation while spending less on utilities: Staying competitive in today’s manufacturing landscape demands running operations as efficiently as possible…
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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…
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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…
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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…
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Video Clip: Silo Monitoring
A video clip (6 min 53 sec) from The Smart Manufacturing Journey webinar a case study, Silo Monitoring.
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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…
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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.
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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…
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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.
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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…
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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…
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Webinar: Simulation + Emulation
When evaluating potential system design options or validating automation system design functionality, choosing the right software tool and approach can…
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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…
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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
Modernized Process Control System
A process control system update presents multiple challenges - especially when the system is over 25 years old with modifications…
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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…
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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…
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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
New Batch System Yields High Returns
A global snack baker eliminated quality losses and downtime, and increased yield by 30% after replacing their batch management and…
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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…
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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…
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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…
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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.…
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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,…
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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…
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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…
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…
