Perth County Ingredients cuts reactive maintenance 54% using Fiix and PLC integration

Perth County Ingredients retools maintenance with rapid Fiix and PLC integration

Rockwell Automation is announcing that Perth County Ingredients (PCI), a Canadian dried‑egg processor, dramatically reduces reactive maintenance after deploying Rockwell’s Fiix CMMS and the Fiix Asset Risk Predictor with PLC integration by Majik Systems. PCI moves from a 100% “run‑to‑failure” model to a data‑driven regime in which real‑time vibration, temperature, pump current, torque and other machine‑health data flow from plant PLCs into Fiix. Technicians receive tablets and mobile access to work orders, SOPs, QR‑coded documentation and the building automation system, supported by Wi‑Fi upgrades that enable seamless factory‑floor connectivity.

Automated threshold monitoring and instant work‑order generation go live in about two weeks with no manual data entry, giving managers 24/7 visibility even when staff are offsite. PCI records a 54% reduction in reactive maintenance and a 47% decline in after‑hours call‑ins, and reports more than US$40,000 in annual maintenance savings and a threefold return on the project investment. The company also cites fewer pump and bearing replacements, reduced equipment‑failure frequency and the ability to reallocate labor from emergency responses to higher‑value tasks such as planning and preventive work.

The initiative proves scalable: PCI’s parent rolls out Fiix across seven additional facilities to enable centralized multi‑site oversight and standardized practices. Building on condition‑based maintenance, the plant leverages the Asset Risk Predictor to prioritize work, extend asset life and inform capital decisions, positioning the group for further automation and sustainability improvements. Rockwell frames the project — announced from Milwaukee on Feb. 17, 2026 — as a rapid‑deployment example that ties measurable KPIs to a digital maintenance roadmap.

Nordic feedmaker adopts Fiix to standardize maintenance

Rockwell is also collaborating with DLG Group to deploy Fiix CMMS across northern European feed and agri‑product plants, a programme that begins centralizing maintenance data and spare‑parts control. DLG sees mean time between failures improve within a month and expects about a 10% downtime reduction within a year, while managers gain real‑time maintenance queues and better coordination with production planning.

Fiix as a scalable platform for food and agriculture operators

Rockwell is positioning Fiix as a repeatable solution for food and agricultural manufacturers seeking to convert operational data into uptime, inventory and cost‑of‑ownership gains. The company highlights multi‑site scalability, sensor integration and a pathway from computerized maintenance to predictive‑maintenance capability across heterogeneous equipment.