Integrated Robotics and Control Systems Deliver 45% Production Boost at Aquazania Waters Project and Industry

System Integration & Control Systems Design

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September 2025 System Integration & Control Systems Design

Project and Industry

Process Dynamics designed and commissioned a state-of-the-art Reverse Osmosis (RO) water purification and automated bottle filling plant for Aquazania Waters in Linbro Park, Johannesburg. The facility targets premium water quality, high production capacity, and energy-efficient automation, making it one of the most advanced water bottling operations in South Africa.

Project Outcome

Since commissioning, the plant has achieved:

• 45% increase in overall production output

• Over 30% gain in operational efficiency

• Reduced cycle times, improved product flow, and lower energy consumption per unit

These results are the direct outcome of fully integrated automation, robotics, and advanced process control, providing Aquazania with a future-proof, scalable production platform.

Biggest Challenge & Our Solution

The main challenge was integrating existing legacy infrastructure with a state-of-the-art automation system, including Siemens PLC/HMI/SCADA and real-time monitoring.

Solution:

Process Dynamics implemented a unified control system using Siemens PLCs, HMIs, and SCADA, enabling seamless communication and control across both legacy and new equipment. This ensured operational continuity while providing precise process oversight and enhanced efficiency.

Key Technologies and Tools Used

• Siemens PLCs, HMIs, and SCADA for unified control and monitoring

• Fanuc robots for automated palletising and depalletising

• SEW-Eurodrive motors and Control Techniques Commander S100 VSDs for conveyor control and buffering

• SMC pneumatics for energy-efficient automation

• IFM sensors and flow meters for real-time process monitoring

• Siemens energy meters for detailed consumption tracking

One Thing We’d Do Differently Next Time

Engage earlier in the conceptual design phase with cross-disciplinary teams to allow more iterative testing of cycle optimisation algorithms, reducing commissioning time and improving initial system tuning.

Unique Selling Point

“Process Dynamics delivers fully integrated, customer-focused automation solutions that combine technical excellence with seamless communication across complex systems, enabling unmatched operational precision and efficiency.”

Project Highlights

• Full automation of the RO purification and high-speed filling plant

• Integration of conveyors, robotics, and Siemens SCADA for smooth, energy-efficient operation

• Cycle-time optimisation algorithms to maximise throughput and equipment longevity

• Customer-focused design ensuring accurate, reliable, and visually appealing operation

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System Integration & Control Systems Design

Integrated Robotics and Control Systems Deliver 45% Production Boost at Aquazania Waters Project and Industry

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