Process Control & Automation

ANZCO, like many plants, have many different control systems and needed a solution that would integrate with them all to provide cohesive reporting across the plant areas.

As a recognised Rockwell system integrator, Swarm Intelligence is familiar with the power of Rockwell‘s FactoryTalk View and VantagePoint products to present a live view of the plant as well as provide sophisticated trending and reporting functionalities.

In conjunction with ANZCO's IT department in Christchurch, Swarm Intelligence designed and implemented a system that met their IT requirements of virtualisation. This meant locating the SCADA and Logging computers centrally in their Christchurch data centre, and utilising VMWare to provide a fully redundant solution so that data is not lost. The wealth of drivers available using RSLinx mean data is collected locally from the many different PLCs from different manufacturers served up to the main servers in Christchurch. Should the Christchurch link fail then the local data servers buffer the data until such time the link is restored.

On site operators, technicians, and managers now use the clients to connect to the Christchurch network, giving them the ability so view the plant information screens as well as view trends and reports.

Swarm Intelligence have remote access to both the Christchurch system hub and Ashburton site to provide assistance and maintenance.  Rockwell’s VPN support means we can support every aspect of the system, from operator HMI’s to manager’s reports.

The result is a successful implementation, with potential to encompass data from other ANZCO sites.

Software overview



An EMI which gives you manufacturing information when you need it, to make better informed decisions.

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FactoryTalk View


A versatile dedicated HMI application that's a powerful solution for machine-level operator interface devices.

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Studio 5000


Delivers standardised framework for discrete, process, batch, motion, safety and drive-based systems.

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Unified, software defined Virtualisation software.

Software overview

Developing dedicated software, customised to ensure uncompromised accuracy for critical component placement.

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The mechanics of hydraulic positional control are challenging due to the high speed automated process involved. This proved beyond a doubt the most challenging aspect of Swarm’s involvement.

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Clever mechanical engineering goes hand in hand equally with clever software, in order to create a unique and fit for purpose solution. The intelligence lies in the monitoring of this - demonstrating precision control with intelligent software!

Hamish McIntyre,
Engineering Manager Springfree New Zealand Ltd

ANZCO have already seen the benefits in Ashburton, here are just a few:

  • Reduced energy use by 10.7% with energy costs down by 5.3%.
  • Better chiller management and insights into actual capacity.
  • Real time performance of plant.
  • Compliance and reporting information moved to single portal.
  • Lowered IT investment by virtualisation of the automation layer.

The benefits gained by Springfree's from collaborating with Swarm Intelligence:

Human intervention minimised

Minimising operator influence whilst maintaining consistent manufacturing.

Ensuring personnel safety with high quality assurance - this is only achievable when well designed automation is implemented.

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The ability to set machinery to exact requirements leaving it do its job, equals mass production.

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Cost recovery

With high end automation the initial capital investment is swiftly recovered due to improved productivity and quality.

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Ongoing support

Any issues or concerns Swarm Engineering are immediately available to provide a solution.

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