CUSTOMER SUCCESS STORIES
Powering Global IoT Operations at Scale with Puratos
Enabling Global Production Operations with IoT and Data Intelligence
Puratos is a global leader in high-quality ingredients for bakers, pastry chefs, and chocolatiers. With more than 75 production sites across over 50 countries, innovation is part of their DNA, not only in the products they create but also in how they manufacture them. Their strong focus on digitalization, with IoT as one of the core technologies, reflects their commitment to continuous improvement and operational excellence.
In order to enhance efficiency, quality, and sustainability across all sites, Puratos actively leverages IoT technology for real-time monitoring of machine health, energy consumption, and production performance. Instead of deploying isolated, one-off IoT solutions per site or per application, Puratos partnered with VersaSense to establish a scalable, centralized, and modern IoT data infrastructure, that empowers local teams with the right insights while maintaining global visibility and control over all deployed IoT infrastructure.
CHALLENGES & REQUIREMENTS
Unifying IoT Across Global Sites, without Fragmentation and Silos
With production sites spread across the globe, Puratos has long recognized IoT-enabled data as a key driver for operational excellence across different use cases. Over the past years, the company has strategically adopted IoT to support a range of industrial applications, including:
Overall Equipment Effectiveness (OEE): gaining real-time insights into machine and production line performance
Predictive Maintenance: anticipating failures before they disrupt production
Energy and Utilities Monitoring: tracking energy usage and supporting sustainability goals
Asset Intelligence: monitoring and optimizing the performance of critical production assets
However, implementing these applications at scale came with a major challenge: how to deploy and manage IoT consistently across dozens of independent sites, without ending up with fragmented tools, isolated data, and siloed operations?
APPROACH
One Platform, Many Sites: Standardizing IoT at Scale
Instead of deploying isolated systems and a patchwork of tools for each site, Puratos partnered with VersaSense to realize a unified, modern IoT-enabled data infrastructure that could scale globally while empowering local teams with data intelligence and the right insights.
Their vision required a IoT data platform that could:
Support multiple IoT applications, such as OEE, predictive maintenance, and energy monitoring, from a shared sensor infrastructure
Standardize IoT device, security, and data management across all locations
Give local operations teams control over their site’s infrastructure and direct access to their own data
Integrate seamlessly with enterprise historian systems like AVEVA PI, as well as other in-house platforms
The goal wasn’t just to deploy and connect IoT sensors, but to establish a repeatable, scalable approach that’s simple and intuitive for local teams, giving every site the tools to explore, understand, and act on real-time data.
SOLUTION
A Scalable Infrastructure, Built for Local and Global Needs
Each Puratos plant operates its own local IoT infrastructure, using a combination of LoRaWAN, mesh networking, or NB-IoT-enabled sensors depending on site conditions and application needs. This flexibility across different sensor and wireless technologies ensures reliable and secure data collection even in complex industrial environments. Depending on the application, sensor intelligence is applied at the edge, performing computations and initial data processing directly on the sensor. The processed data is then securely routed through local gateways and transmitted to the cloud platform.
From a platform perspective, local teams benefit from a powerful environment that puts them fully in control of their IoT infrastructure. Through an intuitive web interface, they can locally manage their sensors and gateways, monitor connectivity and security, and organize associated data and assets, without requiring specialist IT expertise.
They have access to:
Site-specific views of all sensors, connected data points, and production assets
Fine-grained permissions to configure sensors, manage alerts, and set thresholds where relevant
Intuitive tools to analyze and visualize live and historical data, enabling real-time insight and action
Flexible automation options to define alerting rules and forward data to third-party systems such as MES, SCADA, or historian platforms
Meanwhile, global managers retain full visibility and control across all sites. They can monitor sensor performance, detect behavioral trends, and benchmark operations worldwide, combining global oversight with local empowerment.
INTEGRATION
Seamless Integration, Contextualized Visualization
The VersaSense IoT platform is tightly integrated with Puratos’ enterprise historian systems, including AVEVA PI and local plant historians. Through declarative configuration, all individual sensor data is automatically routed, preprocessed, and injected into the correct asset hierarchies, ensuring it arrives in the right format, with minimal latency and zero manual intervention.
At the edge, preprocessing pipelines allow sensor values to be enriched, normalized, or transformed before entering enterprise systems. Whether forwarding raw signals, derived indicators, or application-specific aggregates, the platform ensures consistency across locations and use cases.
Visualization is built in, enabling engineers and operators to create dynamic dashboards that combine real-time and historical views. These dashboards support OEE monitoring, predictive maintenance insights, and energy and utilities analysis, while being tied to real production context. By integrating with local plant data, users can interpret information in its real production context, uncovering patterns tied to specific machines, production lines, or shifts.
RESULTS
Scalable Control. Local Empowerment. Real-Time Insight.
With VersaSense’s platform running across multiple production sites, Puratos now operates a single IoT system that supports both company-wide coordination and site-specific control.
Sensor data from all sites is continuously collected and streamed to the cloud, giving Puratos a real-time view of its production environment. This central visibility enables better decision-making at the corporate level while helping teams compare performance across plants and identify opportunities for improvement.
On the shop floor, local operations teams can monitor live data, detect issues early, and make quick adjustments. This has improved response times, reduced downtime, and increased confidence in daily decision-making.
Behind the scenes, the platform integrates seamlessly with enterprise systems such as AVEVA PI. Built-in tools allow users to route and structure data correctly, ensuring a smooth handoff to existing historian and analytics platforms, without any custom development required.
As IoT adoption within Puratos continues to expand, the system scales effortlessly with it. Whether onboarding new sites, rolling out additional use cases like energy tracking or predictive maintenance, or adding new sensors, the platform is ready, with built-in security, access control, and compliance.
The result: a unified, modern IoT-enabled data infrastructure that empowers every team, local and global, with the tools to work intelligently with data and continuously improve how things run, day to day.
