Complex Integrations Break Industrial Digitalization
Complex Integrations Break Industrial Digitalization
Embedded Files
Real Data
Without Stopping Production
Real Data
Without Stopping Production
ZentinelMDS solves the complexity of connecting industrial machine data to IT systems, providing an edge platform that unifies data capture, processing, and delivery in a simple, secure, and scalable way.
Our technology allows you to integrate any machine—regardless of its protocol or age—and transform its data into structured information ready for use in IT applications, without the need for complex development or access to IT systems.…
Non-invasive data acquisition from multiple machines
Non-invasive data acquisition from multiple machines
ZentinelMDS allows you to capture data directly from machines using a distributed architecture based on Ethernet networks and ZentNode smart adapters.
These devices connect to existing machine signals - digital or analog - and process the information at the source, reducing the complexity of integration and improving the quality and accuracy of the data.
The data is aggregated in ZentEdge and delivered in a structured way to IT systems using MQTT and SQL, allowing their immediate use in IT applications. This architecture simplifies cabling, minimizes deployment effort and allows you to easily scale data capture to multiple machines without relying on PLCs or complex networks.
ZentEdge
ZentEdge
An IT interface for all machine data
An IT interface for all machine data
ZentEdge is an industrial microserver that provides a standard IT interface for machine data using MQTT and SQL, allowing fast, secure and scalable integration of all types of IT applications
ZentEdge is compatible with a wide variety of industrial protocols and devices, including OPC-UA, Modbus, EtherNet/IP, Profinet, LoRaWAN or USB, which allows you to connect both modern machinery and legacy equipment without complex developments. ZentEdge is designed to be installed directly on the machines
Write an email to ZentONE@ZentinelMDS.com
Capture data from any machine → direct integration with IT → all on-premise, cyber-secure and without programming.
Capture data from any machine → direct integration with IT → all on-premise, cyber-secure and without programming.
More than 70% of factories manually measure the operation of their machines.
The result is a loss of 20-30% of capacity due to invisible stops and micro-stops.
ZentinelMDS eliminates that invisibility without touching the PLC or stopping the line: installation in hours, local data in SQL, operation dashboards, integration with ERP and AI. Measurable results from the first machine.
Key benefits:
+15-25% OEE typical in real lines (without new machinery)
Quick installation without machine stops
100% on-premise → data never leaves your network
Compatible with industry standard signals (24VDC, 0-10V, 4-20mA, Modbus)
Write an email to ZentONE@ZentinelMDS.com to know more
Digitalize, Integrate and Scale in 3 Phases
Digitalize, Integrate and Scale in 3 Phases
Digitalize your first machine with ZentONE
Digitalize your first machine with ZentONE
Install a ZentONE system to measure the performance of your first machine and obtain objective and continuous information about its production.
Measure production, rejections and downtime in real time.
Automatically calculate the General Efficiency of the Equipment (OEE).
Record and visualize machine data locally, without relying on the corporate network or the cloud.
Use Artificial Intelligence with ZentONE data to quickly identify opportunities for improvement in that machine
Integrate your ERP with ZentOPS
Integrate your ERP with ZentOPS
ZentOPS allows you to link ZentONE's real-time information with the company's ERP.
Send and receive order information directly with your ERP using standard communication mechanisms
Allow the operator to select and manage the active production order on a digital workstation.
Traceability of batches of products and raw materials
Automate the link between actual production and planning.
Optimize the Production of the Whole Plant
Optimize the Production of the Whole Plant
Replicate ZentONE easily on other machines for a completely digital view of your plant's production
Install a ZentONE system with ZentOPS on each machine.
Add new ZentNode adapters to digitize specific signals such as temperatures, pressures, consumption or vibrations
Compare the efficiency of the various lines and machines
A data model common to all machines allows the use of advanced AI models to optimize plant-wide production
ZentONE® Success Cases
ZentONE® Success Cases
Chocolate Packaging Line (España)
Chocolate Packaging Line (España)
Comprehensive monitoring of a workstation composed of two mechanical packaging machines of great longevity (>20 years) and a modern PLC-controlled box former.
The Challenge
Obtain accurate OEE metrics in machines of different technological generations, control the real-time consumption of critical raw materials (aluminum, cases and boxes) and synchronize manufacturing with the corporate ERP system.
ZentONE solution
Implementation of a ZentEdge microserver with eight interconnected ZentNode adapters via Single Pair Ethernet network. External sensors were installed in the old machines to detect the flow of the product, while a direct capture of existing electrical signals was carried out in the former.
An application developed by the user sends the ERP production orders to the operators and collects the OEE information registered by ZentONE.
Investment
9,900 € (Configured system + 2 days of specialized technical assistance for commissioning).
Vegetable Oil Botling Line (Uruguay)
Vegetable Oil Botling Line (Uruguay)
Modern packaging line with machinery from four different suppliers where the actual yield was significantly lower than the theoretically expected.
The Challenge
Unify the vision of the entire line without incurring the exorbitant costs of solutions based on traditional SCADA systems or compromising the security of PLCs through uncontrolled external access.
ZentONE solution
Each electrical cabinet was equipped with a ZentNode system that captures flow signals from parts in a non-intrusive way. The ZentEdge line header system acts as a concentrator, generating large-format dashboards for the plant. This architecture guarantees a total physical separation between the control network (OT) and the management network (IT), protecting the assets against cyberattacks.
Results
Commissioning in just 2 days and a 19% reduction in unemployment periods after only two months of data analysis.
High Speed Blottling
(Coca-Cola Brasil)
High Speed Blottling
(Coca-Cola Brasil)
Critical filling and labeling station with a production of 45,000 bottles/hour, operating in intensive regimes of 24/6 with PLCs of 30 years without official support.
The Challenge
Measure the OEE accurately without intervening in the control logic of obsolete PLCs and export the data to the central plant SCADA using standard industrial protocols.
ZentONE solution
Installation of a ZentEdge microserver with ZentNode OEE adapter connected to photoelectric cells that detect the entry of full bottles and the exit of compliant products after quality control.
The integration with the SCADA system of the plant was resolved by Modbus / TCP, allowing a constant flow of data to the production office without putting at risk the stability of the old machinery
Manufacturing of Electrical Connectors (Asia)
Manufacturing of Electrical Connectors (Asia)
Deployment in a high-precision plant to monitor CNC lathes, milling machines and plastic injectors from various manufacturers.
The Challenge
Visualize the performance of each machine in real time, digitize batch selection to eliminate human errors and centralize historical data for continuous improvement analysis.
ZentONE solution
A modular system was installed per machine consisting of a ZentEdge and a ZentNode OEE adapter. The solution includes an intuitive HTML operator panel with support for peripherals (barcode reader and keyboards). The system captures the critical signals of "In Cycle" and "Alarm" directly from the electrical panel, integrating the production into the local SQL database of each server.
Investment
3,900 € per machine (System configured and ready for a quick installation by the customer himself).
ZentONE® Use Cases
ZentONE® Use Cases
Packaging Lines
Packaging Lines
Real-time automatic OEE
Detects stops, micro-stops, format changes and speed losses without manual intervention.
Complete traceability
It records analog signals (consumption, sealing pressure, filling level, torque, flow rate, etc.) to guarantee quality, avoid defects and maintain total traceability of each batch or unit produced.
Compatible with any packaging line
It is installed in minutes without modifying controls or stopping production, with easy integration to ERP.
Injection Molding
Injection Molding
Real-time automatic OEE
Detects stops, mold change time, microstops and cycle losses without manual intervention.
Ensures quality
Monitors the pressure in the mold before each cycle to avoid defects and maintain total traceability of each cycle and piece produced.
Compatible with any machine
It is installed on old or modern machines without modifying the original control, with easy integration to ERP.
CNC Machines
CNC Machines
Real-time automatic OEE
Detects tool holds, microstops, and loss of speed without manual intervention.
Registration of key parameters
It records analog signals (spindle speed, load, hydraulic pressure, etc.) to ensure quality and prevent defects or breakages.
Compatible with any CNC
Installable on old or modern machines without modifying the original CNC, with easy integration to ERP.
ZentONE® Features
ZentONE® Features
Simplicity
Simplicity
ZentONE is easy to install and maintain
Without programming controllers
Without modifying the machines
Without configuring networks or drivers
Cibersecurity
Cibersecurity
ZentONE provides an isolated and encrypted data path between your machines and your information systems.
Your machines are fully protected against any cyberattack on your computer system.
Compatibility
Compatibility
The use of standard protocols ensures compatibility with your current infrastructure
ZentONE can be applied to all types of machines, regardless of their age or control technology.
ZentEdge Microserver
ZentEdge Microserver
The ZentEdge microserver is a robust device designed to operate in industrial environments. Its compact and impact and vibration resistant design makes it ideal for use in factories or warehouses.
This microserver includes all the necessary services to operate autonomously, without depending on the internet. Its local database and application services allow real-time data collection and processing, ensuring information privacy and security.
ZentOPS - ERP Integration
ZentOPS - ERP Integration
A lightweight and efficient link between real-time production data captured by ZentONE and the company's ERP, eliminating the need to implement a traditional MES system and allowing direct, secure and bidirectional integration without complex intermediate layers.
With ZentOPS you can automatically synchronize production orders sent from the ERP, allow the operator to select and manage the active order on the digital workstation, record the actual performance of the machines (OEE, quantities produced, stops, etc.) and return this information to the planning system to maintain complete traceability and instantly updated data-based decisions
ZentNode Smart Adapters
ZentNode Smart Adapters
ZentNode simplifies access to machine data by directly connecting sensor signals and sending processed information using MQTT to information systems.
Without programming PLCs
Without configuring automation networks or communication drivers
No risk of cyber attacks
ZentNodeOEE
Meases the operational efficiency of any machine from 2 signals
ZentNodeCT
Parts counter, speed or production times (up to 3Khz)
ZentNodeMT
Measurement of energy, water and raw materials consumption from pulses
ZentNodeEM
Measurement of energy consumption with 4-20 mA current transformers.
ZentNodeAL/C
Monitoring of 0-10V (AL) or 4-20mA (ALC) analog signals such as level, pressure or temperature
ZentNodeVM
Monitoring of machine vibrations according to ISO-10816, using vibration sensors with 4-20 mA output.
ZentNodeIO
Adapter with 2 24VDC channels configurable as Input or Output independently
ZentNode
Modbus
Integrates Modbus RTU devices into the ZentONE ZentNet network
ZentinelMDS Services
ZentinelMDS Services
Consulting
Consulting
ZentinelMDS can advise you on how to automatically connect the data on your machines with your information systems.
With just a teleconference we can prepare a proposal for the digitization of your machines adjusted to your needs and budget
Support
Support
ZentinelMDS offers training and support services tailored to your needs, including:
Training courses for your technicians
Device Configuration
Single Pair Ethernet Network Design
Installation and commissioning assistance
Customized Solutions
Customized Solutions
ZenitnelMDS provides systems tailored to the specific needs of users, including:
Development of ZentONE applications (operator screens, data logic...)
ZentOPS configuration for communication with ERP systems
EUROPA
ZentinelMDS S.L.
EUROPA
ZentinelMDS S.L.
DFactory
Calle 27, nº 10-16, Zona Franca
08040 | Barcelona | España
AMÉRICA
ZentinelMDS Ltda.
AMÉRICA
ZentinelMDS Ltda.
ACATE
Rodovia SC 401, nº 4120 | Sala 3
Saco Grande | Florianópolis | SC
CEP 88032-005 | Brasil
Write an email ZentONE@ZentinelMDS.com to know more about our solutions
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