Protecting Your Plant from Downtime
Industrial automation relies on PLCs, SCADA systems, and HMI projects to keep production running smoothly. Yet, even small mistakes — a misapplied change, a hardware failure, or a network glitch — can halt operations and lead to costly downtime. Automated backup and recovery systems ensure that your critical control assets are always protected, recoverable, and traceable.
Why Automated Backup Matters
Manual backups are error-prone. Engineers may forget to copy the latest PLC program or HMI project, or backups may be stored inconsistently across workstations. Automated systems solve this by:
- Scheduling regular backups across all automation assets.
- Storing files in a centralized repository for easy access.
- Tracking changes to ensure every modification is documented.
The result? Reduced human error, faster recovery, and higher operational reliability.
Risks Without Automation
Plants that rely on manual backup processes face several challenges:
- Unrecoverable Changes: Lost or overwritten PLC programs can halt production.
- Extended Downtime: Manually restoring files is slow and may introduce new errors.
- Lack of Traceability: Without logs, it’s difficult to identify when and why a change occurred.
Automated backups mitigate these risks and help maintain operational continuity.
Key Capabilities of Automated Backup & Recovery Systems
A robust system typically provides:
- Scheduled Backups: Regular backups of PLC, SCADA, and HMI projects.
- Change Detection & Logging: Identify what changed, who made the change, and when.
- Centralized Storage: Easy access to all versions of control system files.
- Fast Restore Options: Quickly revert to previous versions to minimize downtime.
- Integration with Disaster Recovery Plans: Align backups with broader operational continuity strategies.
Real-World Examples
- Consumer Goods Manufacturing: A plant implemented automated backups across all PLCs and SCADA systems. When an unintentional change caused a line halt, the engineers restored the previous version within minutes, avoiding prolonged downtime.
- Mining Operations: A site experienced a network failure that affected PLC connectivity. Thanks to scheduled backups, the engineers recovered all programs without manual reconstruction, keeping production on track.
- Global Automotive Supplier: Multiple production lines across different sites were synchronized using automated backups. Engineers could quickly recover from software conflicts and maintain uninterrupted production schedules.
Getting Started
- Assess Your Assets: Identify all PLCs, HMIs, SCADA projects, and other critical control files.
- Implement an Automated Backup Solution: Set schedules, central storage, and change logging.
- Test Recovery Procedures: Ensure backups can be restored quickly and accurately.
- Monitor & Refine: Regularly review backup performance and adjust schedules as needed.
Automated backup and recovery are essential to maintain uptime, protect critical assets, and support audit readiness in industrial plants. By proactively managing backups, your team can focus on optimizing production instead of reacting to preventable downtime.
BUSINESS UNITS
Process Control Systems (PCS)
- Programmable Logic Controllers (PLC’s)
- Visualization (HMI and SCADA Systems)
- Software Standards (Abnormal Situation Management)
- Data Historian
- Remote Operating Centres
- Safety Control Systems
Electrical Systems (ES)
- Distribution and Motor Control Centres (MCC’s)
- Intelligent Motor Control
- Advanced Variable Speed Drive Systems
Industrial Information
& Communication
Technology (IICT)
- Industrial Ethernet Networks
- Remote Connectivity
- Cyber Security
- IT Virtualisation
- Manufacturing Execution Systems (MES)
- CMMS
We offer peace of mind project execution knowing that our activities are accredited by ISO9001:2015 Certification and a 5 star NOSA safety certification. This ensures that we maintain a high level of quality assurance and adhere to rigorous Occupational Health and Safety standards during project delivery.
SERVICES
Professional services include each phase of the project lifecycle:
Project management
STARO Integration manages every project with a comprehensive set of tools based on the PMBOK Project Management Standards.
Basic design
STARO Integration has over 25 years’ experience and our experienced engineering team works closely with the customer to understand the initial scope of work for a project and propose a high-level view of the system requirements.
Detailed hardware design
STARO Integration performs the Detailed Hardware Design in line with industry-, OEM- and Quality standards combined with our 25 years of industry knowledge. This is done with continuous client reviews and approval cycles.
Detailed software design
STARO Integration utilise our inhouse software standards as a baseline and with the client determine the standards to be utilised. The Control System Software is then developed utilizing these proven Software standards resulting in a consistent, correct, maintainable control system.
Design drawings
STARO Integration provides Design and Drawing services for instrumentation, field devices and electrical equipment. These drawings including layout, installation, wiring, junction boxes, and cable routing.
Network design
STARO Integration designs according to industry standards as well as vendor specific networks for distributing controllers, I/O, data servers, and operator stations.
Simulation and Factory Acceptance Testing
a FAT plan with checklists tests every loop and HMI/SCADA screen against the Software Design Specification. Quality of workmanship is reviewed against the Quality Assurance check sheets and a punch list of items are resolved before shipping the system.
Site Acceptance Testing and Start-up
After the control system and all the I/O have been installed and commissioned, STARO Integration works with the client to supply the Site Acceptance Testing in accordance with the SAT plan. Site Acceptance Testing proves that the supplied system, including the control logic and operator stations, is interfaced to the field I/O correctly and performs in accordance with the functional design specification.
Training services
STARO Integration can offer either OEM specific training or training specific to a control system project.
Maintenance and support
STARO Integration offers qualified engineers to support the customers installed Control System.
A Service Level Agreement (SLA) makes pre-designated engineers available for pre-planned work or for short notice call outs.
Lifecycle management
STARO Integration can provide the client with strategies, alternatives, and estimates for upgrades and migrations.
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HEAD OFFICE
17 Venus Street, Sasolburg, 1947
+27 (0)16 971 3333
SECUNDA BRANCH
16 Steenkamp Street, Secunda, 2302
+27 (0)17 634 7011
sales@staro.co.za
PROUDLY DESIGNED AND BUILT BY BUNNYPANTS GRAPHIC & WEB DESIGN STUDIO | 2023
