Stratus Reliability at the Edge Success Stories Compendium - Case Study

Case Study Compendium

Modernize and Maximize Reliability at the Edge Twelve monitor and control success stories to learn from

Modernizing Control Architectures for Maximum Reliability and Easy Management with Zero-Touch Edge Computing

Stratus ztC EdgeTM

Organizations need reliable, resilient, and modern computing solutions for

• Up to 5,000 input/outputs (I/Os) • Up to four virtual machines (VMs)

mission-critical monitor and control applications. Zero-touch edge computing provides end users with an optimal platform to modernize legacy control

• High availability or fault tolerant

architectures; deploy industry-leading HMI/SCADA software on-machine, on the

• UL Class I Div 2 certified

plant floor, in the control room, or at the operations center; and integrate best-in-class software to improve operational performance.

Stratus fault tolerant computing platforms from Penguin Solutions® are designed from 40 years of industry experience. By delivering zero-touch edge computing platforms that are simple to deploy and maintain, protect against interruptions and threats, and operate autonomously, Penguin Solutions ensures continuous availability for mission-critical applications.

The following 12 customer success stories showcase how organizations in industries ranging from Oil & Gas to Specialty Chemicals to Pharma are leveraging edge computing to modernize infrastructure, run mission-critical applications with no downtime, and build future-proof control architectures for long-term success.

© 2025 Penguin Solutions Modernize and Maximize Reliability at the Edge Case Study Compendium - 07.2025

Stratus ftServer ®

• 100,000+ input/outputs (I/Os) • 30+ virtual machines (VMs) • Automated uptime layer • Fault tolerant

Midstream Oil & Gas Company One of the largest independent liquid petroleum product pipeline operators in the U.S. owns and operates a diversified network of integrated assets that together provide trusted midstream logistics solutions. With a global terminal network of more than 100 liquid petroleum terminals, over 7,000 miles of domestic pipelines, and millions of barrels of tank capacity, the company needed a reliable solution to help it manage the complex distribution of petroleum-based products.

The company deployed and standardized Stratus ztC Edge, running terminal automation software across more than 100 sites and deployed Stratus ftServer in the control room.

They also replaced legacy PCs and technologies, which improved operational efficiency, added remote monitor and control capabilities, and reduced costly unplanned downtime.

Challenges

As we looked at Penguin Solutions, their technologies, and digital transformation, we came to the agreement that we would continue to use their solution and would standardize that across our operational applications within the terminal space.

Senior Manager of Terminal Operations Midstream Oil & Gas Company

Solution

Unify multiple,

Stratus ztC Edge deployed in

Increased asset lifecycles from

disparate systems

100+ terminals

three years to six years

Modernize legacy technology

Stratus ftServer deployed in the

Eliminated unplanned downtime

applications and PCs

control room

Reduce frequent

Rockwell Automation PlantPAX

equipment failures

Toptech Systems

Reduced information technology (IT) and operations technology (OT) staff workloads

Eliminate significant

Standardized scalable and

unplanned downtime

reliable hardware and software across operational applications 24/7 Stratus support and services

© 2025 Penguin Solutions Modernize and Maximize Reliability at the Edge Case Study Compendium - 07.2025

For the full story, click here

Loginet & Petra Srl Petra Srl owns and operates one of Italy’s largest oil depots, loading hundreds of trucks and handling millions of liters of oil and gasoline each day. To improve the efficiency of depot operations, Petra runs Nuovo Petrol, a next-generation terminal automation solution from experienced SI, Loginet. This solution controls and monitors all terminal procedures and processes—from access control and weigh stations to deliveries in the bays and paperwork issuances.

With the Loginet solution and Stratus ztC Edge platforms, Petra automated manual processes and integrated disparate terminal systems to reduce risk, enable real-time data, and centralize visibility of operations. The company reduced depot load times by 33% and has experienced zero downtime since adopting Stratus edge computing a decade ago.

Challenges

Solution

Automate terminal operations

Stratus ztC Edge in paired

to improve accuracy, ensure

fault-tolerant configuration

Petra hasn’t had an unplanned outage in 10 years. They’ve

security, maximize safety, gain

deployed in the control room

Connected real-time operations

never experienced any business disruption with Penguin

efficiency, and reduce costs

Solutions as their foundation. When our customers need that

Loginet Nuovo Petrol Terminal

(ERP) and customs reporting

Manage 35 tanks for

extreme level of reliability, we will continue to rely on Penguin

oil-product storage, with

Solutions for continuous computing.

approximately 5,000 tons of product shipped daily Gianluigi Campisano Automation Engineer, Loginet

Operational visibility for analysis, alerting, and improvement

Automation System Loginet IBIS LT2 Badge Reader Loginet GraL Terminal

Reduced filling time by 33%

to enterprise resource planning

Enabled depot-wide visibility into operations by unifying systems and ensuring data capture with edge computing Experienced zero unplanned downtime for terminal automation system for 10 years using Stratus edge computing platforms

© 2025 Penguin Solutions Modernize and Maximize Reliability at the Edge Case Study Compendium - 07.2025

For the full story, click here

Streamline Innovations Streamline Innovations develops and operates a proprietary process for removing toxic hydrogen sulfide (H2 S) from Oil & Gas, water, wastewater, landfills, and biogas. To succeed in the competitive oilfield services market, the company developed a visionary solution called the ValkyrieTM Intelligent Platform to bring AI-powered predictive maintenance, remote monitoring and control of precise chemical processes and operations, and 99.5% uptime to remote oilfield equipment.

The ValkyrieTM Intelligent Platform integrates an Ignition HMI/SCADA with Azure Cloud, MS Dynamics ERP, FOG instrumentation, programmable logic controller (PLC) programming, AI/ML software, and more using a single Stratus ztC Edge computing platform with built-in redundancy and virtualization. This platform offers high-precision process control with “tiered” intelligence to monitor and analyze performance of remote assets.

Challenges Identify a compute platform to

Stratus ztC Edge deployed on

Enabled real-time analysis, HMI,

combine IT and OT capabilities

the skid

and tracking of 50 KPIs from 350

We selected the Stratus ztC Edge because it provides

for monitor and control of

redundant processing, high uptime, significant computing

complex chemical processes in

power, and virtual machines (VMs). This gave us the ability to

rugged environments

replicate units across the field, by providing a VM of ignition

Operate with limited data

and VM of the database separately on the same unit.

connectivity and limited staffing

Dr. Peter Photos CTO, Streamline Innovations

© 2025 Penguin Solutions Modernize and Maximize Reliability at the Edge Case Study Compendium - 07.2025

Solution

in remote Oil & Gas locations Achieve 95% uptime and meet customer automation budgets

Inductive Automation Ignition PostgreSQL database and Python Seeq

miles away Reduced onsite staffing requirements by 66% Enabled AI-powered predictive maintenance Achieved 99.5% uptime, surpassing 95% customer SLA

For the full story, click here

Breton Italy-based Breton is a leading manufacturer of equipment, machines, and facilities that produce and process engineered stone, natural stone (marble, granite, and ornamental), and metals. The company modernized its infrastructure to create Industry 4.0 manufacturing environments where unplanned downtime is not an option and OT staff useability is critical to unburden IT staff.

With the goal of innovating their production processes and enhancing their business performance, Breton focused on two key objectives: business continuity and easy deployment and management. Partnering with Wonderware Italia, they incorporated Stratus ztC Edge, leveraging its easy-to-support high availability/fault tolerance and built-in virtualization to run AVEVA System Platform, HMI/SCADA, and Historian applications.

Challenges Eliminate unplanned machine

Stratus ztC Edge deployed on

Consolidated four AVEVA

downtime to ensure business

the plant floor

applications onto a single

Penguin Solutions’ unique box of available technology—

continuity for customers

virtualization, redundancy, protection, security, customizable

Reduce engineering and

availability, and industrial interoperability—is a leap forward over traditional IPCs and server configuration.

Michele Vario Original Equipment Manufacturing (OEM) and Business Development Director Wonderware Italia

© 2025 Penguin Solutions Modernize and Maximize Reliability at the Edge Case Study Compendium - 07.2025

Solution

setup time to speed delivery to customers Empower OT staff with a simple

AVEVATM System Platform System integration by Wonderware Italia

Stratus ztC Edge compute platform via virtualization Improved customer experience by reducing installation and preparation times by eight hours

compute infrastructure on the

Loaded to add VM images and

factory floor

system upgrades in 20 minutes

For the full story, click here

Bradbury The Bradbury Group of manufacturing companies is dedicated to producing high-quality, productivity-enhancing metal processing equipment for customers around the world.

They needed a solution that readied their customers as well as their own operations for digitalization and efficiency.

By adopting the Stratus ztC Edge platform running Rockwell Thin Manager® and FactoryTalk® for their metal rolling machines, Bradbury Group was able to move from multiple standalone stations to a centralized distributed visualization platform. This switch reduced costs, resolved downtime issues, and revealed a new profit driver for their business providing customer support services.

Challenges Increase machine efficiency

Stratus ztC Edge deployed on

and flexibility by adding

the plant floor

Stratus ztC Edge is designed to provide remote application

compute capability

management, more rapid and efficient multi-site deployment,

Reduce development,

improved security, and high availability of critical business operations and applications.

deployment, and revision update times

Craig Resnick Vice President, ARC Advisory Group

Increase customer uptime with quick replacement hardware, redundancy, and automated system backup

© 2025 Penguin Solutions Modernize and Maximize Reliability at the Edge Case Study Compendium - 07.2025

Solution Eliminated unplanned downtime Used virtualization to

Rockwell Automation

consolidate workloads on a

ThinManagerTM

single Stratus ztC Edge

Rockwell Automation FactoryTalk® View Site Edition

computing platform Enabled support services as a new customer offering Reduced engineering and maintenance costs

For the full story, click here

Enginuity Global & QuarterNorth Energy QuarterNorth Energy, a leading Oil & Gas producer that operates deepwater, shallow, and shelf assets in the Gulf of Mexico, needed to modernize infrastructure and process control technology on its Bullwinkle oil platform. This project was critical for improving safety and responsiveness, eliminating costly downtime, and driving operational excellence.

QuarterNorth Energy turned to Enginuity Global, an SI with expertise in process automation, control, and field services. In only 45 days, Enginuity upgraded all of the PLC panels and centralized monitor and control applications by running their Rockwell distributed control system (DCS)—including HMI/SCADA and Rockwell Automation Factory Talk Historian—with SQL Server, supporting 6,000 I/Os on a single, fault-tolerant Stratus ftServer platform. The end result: Higher yields, improved safety, and less unplanned downtime.

Challenges Modernize legacy control

Stratus ftServer deployed in the

Consolidated 12 applications

systems and infrastructure on

control room

running on six servers to a

The Stratus ftServer is a tank. It offers a simplistic approach to

existing oil platform

a complex system. Part of our motto at Enginuity is, ’We

Centralize control systems

simplify a complex world.’ Stratus servers definitely help reduce some of that complexity and we were able to save a substantial amount of money using them.

Update servers, workstations, and controllers Improve system response time

Eric Belgard Lead for Automation and Controls, Enginuity

Solution

to boost reaction time,

DCS including HMI/SCADA and

ftServer compute platform

Factory Talk® historian with SQL

Centralized monitor and

Server supporting 6,000 I/Os

control resulted in higher

Anti-virus and cluster management software

decision making, and

System integration by

operational visibility

Enginuity Global

Expand control system/safety

single, fault-tolerant Stratus

Rockwell Automation PlantPAx

yield, improved safety, and no downtime for critical applications Improved system response time by 1000% (from more than 20 seconds to just milliseconds)

system capacity

© 2025 Penguin Solutions Modernize and Maximize Reliability at the Edge Case Study Compendium - 07.2025

For the full story, click here

Rubberlite Rubberlite, a materials manufacturer specializing in custom-engineered polyurethane foams and flexible composite systems, launched a supervisory control systems project with the goal of improving overall data quality, starting with standardizing their HMI/SCADA systems.

Running the AVEVA System Platform on a fault-tolerant Stratus ftServer allowed Rubberlite to digitalize information, standardize data collection at the source, and share that data plantwide. With this critical information and insights in hand, Rubberlite was able to realize an 80% reduction in non-sellable material—a key metric for customer satisfaction and profit—and eliminated application downtime and data loss.

Challenges

We have not had a single downtime event since [Stratus ftServer] has been running in March 2016.

Improve product quality for

Stratus ftServer deployed in

Experienced no downtime since

customer satisfaction

the control room

implementation in 2016

Enable innovation for growth

Launch Supervisory Control

Reduced non-sellable material

Systems Project

production by 80%

AVEVA System Platform

Increased sales by 25%

Eliminate downtime for Process Automation Engineer Rubberlite

Solution

SCADA applications Centralize recipe management for manufacturing repeatability

on Stratus ftServer for fully integrated DCS and data historian

Modernize compute infrastructure Reduce IT maintenance and labor costs

© 2025 Penguin Solutions Modernize and Maximize Reliability at the Edge Case Study Compendium - 07.2025

For the full story, click here

Synthomer London-based multinational specialty chemicals company Synthomer produces additives and raw materials for coatings, paper, textiles, and health and protection products.

Previously, the company’s production facility in Piedmont, Italy was controlled by a collection of PLCs from different manufacturers. These islands of automation operated independently in siloes and were difficult and expensive to maintain and operate.

In 2018, Synthomer modernized the plant’s disparate monitor and control system with a Stratus ftServer running Rockwell Automation PlantPAx DCS, including HMI/SCADA, with the help of SI Progecta. The project drove a considerable increase in production and revenue at the plant by putting in place a simple, standardized, and resilient system.

Challenges Centralize control of siloed

Stratus ftServer deployed in the

99.999% uptime with the

PLC systems from

control room

fault-tolerant Stratus ftServer

Rockwell Automation

Vast data availability empowers

PlantPAx DCS

operators and fuels analytics

System integration by Progecta

Production increase of 30% at

Redundancy at the compute level matched with PlantPAx DCS

different manufacturers

redundancy at the control level is a formidable combination

Solve the expense and

for downtime prevention for mission-critical applications. By partnering with Rockwell Automation to characterize this joint solution, we’re delivering a massive leap forward for operations.

Frank Hill Director, Rockwell Automation, Strategic Alliance at Penguin Solutions

© 2025 Penguin Solutions Modernize and Maximize Reliability at the Edge Case Study Compendium - 07.2025

Solution

complexity of operating disparate PLCs

the company’s Piedmont facility

Migrate to a distributed control system without shutting the plant down

For the full story, click here

RoviSys & Leading Life Sciences Company A leading life sciences company that manufactures cell biology, DNA, RNA, and protein analysis products needed to eliminate downtime and data loss in order to avoid costly disruptions and ensure regulatory compliance.

In one week, RoviSys, a global SI specializing in automation, deployed Stratus ztC Edge and Stratus ftServer running Rockwell Automation PlantPAx, including HMI, at three manufacturing sites. The new production monitor and control architectures provided fault tolerance, simplified validation, converged OT and IT, and reduced total cost of ownership (TCO) by 15-20% compared to a cluster solution. The life sciences company has since experienced no downtime and is able to service its Stratus platforms without dedicated IT support.

Challenges Eliminate downtime and data

Stratus ztC Edge deployed on

Eliminated downtime

loss in batch manufacturing

the production line

and consolidated

With Stratus ftServers’ longevity and durability and

across three sites

streamlined FAT/SAT verification, our customer has a

Ensure data reliability for FDA

top-performing, high-availability solution for the long haul.

regulation, good manufacturing practice (GMP) requirements,

Network Engineer RoviSys

Solution

and Verified Conformity Assessment Program (VCAP) parameters

Stratus ftServer deployed in the

Reduced factory acceptance

control center Rockwell PlantPAx software for campus-wide

software workloads

test (FAT)/site acceptance test (SAT) times from weeks to hours; completed full validation in one week Reduced TCO by 15-20%

Enable manufacturing

and increased compute

operations team to maintain

infrastructure lifespan

and support compute

to 15 years

infrastructure without high-level IT support

© 2025 Penguin Solutions Modernize and Maximize Reliability at the Edge Case Study Compendium - 07.2025

For the full story, click here

DC Water DC Water treats water and wastewater for 1.6 million people in the District of Columbia and neighboring counties in Maryland and Virginia. The company has the largest facility of its kind in the world, treating an average of nearly 290 million gallons per day with a peak capacity of nearly 1 billion gallons per day. Given that DC Water operates one of the largest water utilities, it’s no surprise that a strong HMI/SCADA system was a non-negotiable requirement.

DC Water uses the AVEVA System Platform running on a Stratus ftServer for secure, real-time automation, operations, and control of its water pumping stations, storage facilities, sewage pumping stations, stormwater pumping stations, and fabridams along the Potomac River. To provide continuous service on a massive scale, DC Water deployed a novel fault-tolerant edge computing architecture built on four Stratus ftServer platforms spread across multiple locations to run their sophisticated SCADA systems.

Challenges Deploy SCADA applications

Stratus ftServer deployed in the

Reduced system failover time to

on a resilient,

control center

two minutes for the entire

In our line of work, we need responsive support, and Penguin

fault-tolerant platform

Solutions’ engineers are right alongside us on every issue.

Provide reliable automated

Even if it’s a non-urgent issue, they will call me to follow up

instrumentation for dozens of

until the issue is resolved. They’re very responsive and

sites and facilities throughout

diligent—and that’s just what we want.

the DC Water system Karen Green SCADA Manager, DC Water

© 2025 Penguin Solutions Modernize and Maximize Reliability at the Edge Case Study Compendium - 07.2025

Solution

AVEVA System Platform, InTouch, and Historian Rockwell PLC Schneider Electric PLC

network (a 90% reduction) Enabled fast access to timely data for KPI analysis and regulatory reporting No system downtime in six years,

Create real-time data for

enabling uninterrupted water

analysis and executive/

supply for 1.6 million consumers

regulatory reporting

For the full story, click here

Quantum Solutions and St. Louis Airport As a major transportation hub for 30 years, St. Louis Lambert International Airport is pursuing digital transformation to bring the benefits of Industry 4.0 to aviation.

Previously, technology projects at the airport were piecemeal, disconnected, and limited to one area of the facility at a time. St. Louis Airport leveraged the expertise of SI Quantum Solutions and installed Stratus ftServer running AVEVA software—including HMI/SCADA and Historian. They replaced their aging and disparate systems, integrating the different islands of automation into a complete and centrally connected facilities and building management system and accelerating digitalization across the entire airport.

Challenges Modernize a decades-old

Stratus ftServer deployed in the

Enabled situational awareness

operation at the largest and

control center

and unified operations center

High availability is a big thing. When you're talking about

busiest airport in Missouri

moving an entire airport with multiple legacy siloed solutions

Deploy and scale compute

over into one centralized system then you can't afford to have downtime.

infrastructure to optimize operations for more than 190,000 daily aircraft

Jeremy Meahl Regional Sales Engineer and Owner, Quantum Solutions

Solution

operations across four active runways, two terminals,

AVEVA System Platform System integration by Quantum Solutions

backed by easy-to-use fault-tolerant computing Continuous availability for critical business applications Open and scalable software architecture

and five concourses Support the transport of 15.6 million passengers and 74,000 tons of cargo per year

© 2025 Penguin Solutions Modernize and Maximize Reliability at the Edge Case Study Compendium - 07.2025

For the full story, click here

Dogfish Head Dogfish Head, an award-winning microbrewery located in Milton, Delaware, produces 262,000 barrels of beer in 12 varieties every year. The company had automated its unique hop-dosing process but the solution became obsolete, resulting in unplanned shutdowns and increased cybersecurity risk.

Dogfish Head partnered with Penguin Solutions, deploying Stratus ftServer, to ensure continuous availability for a new manufacturing execution system in order to fuel business growth and future-proof the plant. With Penguin Solutions providing 24/7/365 monitoring and automated processes such as predictive health alerts and online parts replacement, the company has boosted its computing flexibility so that it can keep growing in the brewing sector.

Challenges

With the solution that ProLeiT and Penguin Solutions have provided, we’re no longer limited by our automation system; we’re able to grow and the sky’s the limit.

Liz Stairs Process Improvement Specialist, Dogfish Head

Solution

Ensure the continuous

Stratus ftServer deployed in the

Reduced recipe creation and

availability of critical systems

control center

management time by 80%

Enable the implementation

Brewmaxx from ProLeiT by

Eight additional brews per year

of new equipment as

Schneider Electric

are now possible due to a faster

processes evolve

mashing process

Fortify cybersecurity with an

Reduced hardware footprint

up-to-date automation system

from six legacy servers to one Stratus ftServer

© 2025 Penguin Solutions Modernize and Maximize Reliability at the Edge Case Study Compendium - 07.2025

For the full story, click here

About Penguin Solutions With over two decades of experience as trusted advisors to our valued customers, Penguin Solutions is an end-to-end solutions provider helping solve complex challenges in computing, memory, and LED solutions.

Penguin Solutions designs, builds, deploys, and manages high-performance, high-availability enterprise solutions, allowing customers to achieve breakthrough innovations.

Our Stratus high availability and fault tolerant computing platforms ensure the continuous availability of our customers’ critical applications and data in remote data centers and edge locations.

For more information, visit www.penguinsolutions.com

Contact Us For sales queries, please contact sales@penguinsolutions.com.

To learn more about Penguin Solutions products please call 800-221-6588 or visit www.penguinsolutions.com

© 2025 Penguin Solutions, Inc. All rights reserved. Penguin Solutions, Penguin Computing, OriginAI, and ICE ClusterWare are trademarks or registered trademarks of Penguin Solutions. All other product names, trademarks, and registered trademarks are the property of their respective owners. All company, product, and service names used in this document are for identification purposes only. Use of these names, trademarks, and brands does not imply endorsement.