---
title: "22% Efficiency Gain in Detergent Production"
description: "Discover how Niotek optimized detergent production, resulting in 22% efficiency gain and 18% energy savings with HORUS Optimize."
url: "https://niotek.net/en/case-study/detergent-production-optimization"
language: "en"
---

CHEMICALS • PROCESS MANUFACTURING# Modernizing High-Risk Process Control — Without Replacing Core PLCs.

How a major chemical manufacturer modernized an aging detergent production tower, eliminating alarm floods and operational blind spots — without hardware replacement or production downtime.

Unified Visibility

Intelligent Alarms

Improved Response

0%

Hardware Replacement

## Operating Blind in a High-Risk Process

Operating a Detergent Tower requires continuous, precise control over temperature, pressure, flow rates, and chemical reactions. However, this facility relied on an aging PLC/SCADA setup that introduced serious risks.

- #### Fragmented Process Visibility

Critical parameters spread across outdated HMIs prevented real-time context.
- #### Alarm Floods

Unprioritized alarms generated noise, slowing operator response.
- #### Tribal Knowledge

Operators relied on experience rather than data-driven insights.

LEGACY SYSTEM STATUS

Log #4921

[ALARM] HIGH TEMP ZONE 4 (Ack?)

[ALARM] PRESSURE DROP PUMP B

[ALARM] FLOW RATE MISMATCH

... 42 more alarms suppressed ...

OPERATOR NOTE: "Running blind on Tower B. Checking gauges manually."

THE SOLUTION## Intelligent Automation Overlay

### Alarm Rationalization

Replaced noise with intelligent management. Operators now receive clear, prioritized alerts and early warnings for process instability.

### Centralized Visualization

Replaced fragmented HMIs with a unified SCADA interface. Supervisors gained a single real-time view of the entire tower.

### Brownfield Integration

Integrated directly with legacy PLCs. Process data extracted and contextualized without installing new sensors.

## Before vs. After HORUS

Metric Before HORUS After HORUS Impact Process Visibility Fragmented, Manual Unified Real-Time View Eliminated blind spots Alarm Handling Noisy & Unprioritized Clear & Prioritized Faster operator response Process Stability Reactive Adjustments Stable & Monitored Reduced abnormal events Control Architecture Rigid Legacy System Modern Overlay Ready for future upgrades

// Technical Implementation

## Technical Spotlight

#### Control-Layer Modernization

Enhanced visualization and logic support implemented without altering core PLC programs.

#### Alarm Rationalization

Structured alarm handling aligned with safe operating practices for process industries.

#### Anomaly Detection

Early detection of performance degradation in pumps and heat exchangers.

#### Digital Twin–Ready

A structured process data model now enables future simulation and optimization initiatives.

CTA\_PROMPT.SYS

"MODERN SAFETY STANDARDS. LEGACY HARDWARE. ZERO COMPROMISE."

## Ready to modernize your control system?

Achieve improved safety, higher process stability, and full operational visibility — without CapEx-heavy upgrades.