Salad Dressing Factory

This cookbook walks you through setting up TilliT for a salad dressing and condiment manufacturing facility. By the end, you will have a fully configured site with cooking kettles, holding tanks, a glass bottle line, bulk filling, and portion control lines, plus live machine data flowing in via a Kepware OPC-UA edge connection.

The setup is based on a real-world condiment and dressing factory that blends and cooks raw ingredients in kettles, holds finished product in tanks, and fills into glass jars, bulk containers, and individual portion-control cups for retail and foodservice customers. The plant operates on day and afternoon shifts and uses TilliT for quality checks, cook data capture, filling controls, and live equipment monitoring via edge integration.

All names used in this guide are generic examples. Replace them with your own site, line, and product names.

Prerequisites

Before you begin, ensure you have:

• A TilliT tenant provisioned for your organisation

• An administrator account with access to Settings

• The Excel Add-in installed (recommended for bulk data loading)

For a general introduction to TilliT setup concepts, see Introduction for New TilliT Customers.

1

Create the Site

A site represents the physical location of your factory.

Go to Settings -> Asset Hierarchy -> Sites -> Create

Field	Example Value
Name	Sauce & Dressing Plant
Timezone	Denmark
Location Code	SD

For more detail, see Site.

2

Define Asset Classes

Asset classes group similar types of equipment. A salad dressing and condiment factory typically has the following asset classes:

Asset Class	Description
Area	Top-level groupings (Prepping & Cooking, Production, QA)
Preppers	Fruit and vegetable preparation equipment
Kettles	Cooking and blending vessels
Tanks	Heated holding tanks for finished product awaiting filling
Depalletisers	Empty jar or container unloading
Fillers	Hot-fill machines (glass line, bulk, portion control)
Cappers	Lid or cap application machines
Labellers	Primary and secondary label applicators
Packers	Carton overpackers
Palletisers	Automated palletising

Go to Settings -> Asset Hierarchy -> Asset Class -> Create

Create one asset class for each type listed above. See Asset Class for details.

3

Build the Asset Hierarchy

Assets represent the individual machines and areas. In a condiment factory the hierarchy follows the production flow: preparation → cooking → holding → filling → packing.

Sauce & Dressing Plant
├── Prepping & Cooking (class: Area)
│   ├── Prep Area (class: Preppers)
│   ├── Kettle 1 (class: Kettles)
│   ├── Kettle 2 (class: Kettles)
│   ├── Kettle 3 (class: Kettles)
│   ├── Kettle 4 (class: Kettles)
│   ├── Holding Tank 1 (class: Tanks)
│   ├── Holding Tank 2 (class: Tanks)
│   ├── Holding Tank 3 (class: Tanks)
│   └── Holding Tank 4 (class: Tanks)
├── Production (class: Area)
│   ├── Glass Line (class: Area)
│   │   ├── Depalletiser (class: Depalletisers)
│   │   ├── Filler (class: Fillers)
│   │   ├── Capper (class: Cappers)
│   │   ├── Labeller (class: Labellers)
│   │   ├── Carton Overpacker (class: Packers)
│   │   └── Palletiser (class: Palletisers)
│   ├── Bulk Line (class: Fillers)      ← fills 2 kg – 10 kg containers
│   ├── Portion Control Line 1 (class: Fillers)  ← fills cups 13 mL – 45 mL
│   └── Portion Control Line 2 (class: Fillers)  ← fills cups 13 mL – 45 mL
└── QA (class: Area)                    ← shared quality assurance

Key points

• Kettles cook and blend dressings, sauces, jams, and chutneys. Number kettles based on your actual equipment (e.g. Kettle 1 through Kettle 4).

• Holding tanks keep the cooked product hot and ready for filling. They are typically heated and agitated.

• Glass Line is the primary retail packaging line: jars are depalletised, hot-filled, capped, labelled, overpacked into cartons, and palletised.

• Bulk Line fills large containers (2 kg to 10 kg) for foodservice and industrial customers.

• Portion Control Lines fill individual cups (13 mL to 45 mL) for hospitality and airline catering.

• QA sits at the top level and is shared across all lines.

• Use Display Order to control the sequence assets appear in the UI (e.g. 100, 200, 300).

Go to Settings -> Asset Hierarchy -> Assets -> Create

Create each asset, assign it to the correct asset class, and set the parent asset for child equipment. See Asset for details.

For sites with many assets, use the Excel Add-in to create assets in bulk.

4

Configure Shifts

Shift templates define the working hours for each area.

Shift Template	Start Time	Duration	Description
Day Shift	06:00	8 hours	Standard morning shift
Afternoon Shift	14:00	8 hours	Afternoon shift
Night Shift	22:00	8 hours	Night shift (high-volume periods)

Not every area runs the same schedule. Kettles may run a single extended cook shift while filling lines run two shifts.

Creating shift schedules

Setting up shifts is a two-step process: first, you define the overall shift pattern (Shift Template and its Items); then, you link that pattern to your equipment using a Shift Calendar.

1

Create and Configure the Shift Template

1. Go to: Settings -> Asset Hierarchy -> Shift Templates -> Create.

2. Create the required shift templates.

3. Within each created template, go to: Items

4. Define the specific shift periods, including their start times and durations.

See Creating a Shift Template for details.

2

Assign Shifts to Assets

Once your templates and items are ready, create calendars to map these schedules to the correct assets.

Since not every line runs the same schedule (e.g., Kettle and prep areas often run earlier shifts to have product ready in holding tanks before filling lines start), calendars ensure each asset accurately reflects its real-world operating schedule.

1. Go to: Settings -> Asset Hierarchy -> Calendars -> Create.

2. Add your Shift Template as a calendar Item.

3. Select the relevant asset and apply the template.

5

Set Up Units of Measure

Before creating materials and process variables, define the units of measure your site will use.

Unit	Description
g	Grams (fill weights, small quantities)
kg	Kilograms (ingredient weights, bulk containers)
mL	Millilitres (fill volumes, liquid ingredients)
L	Litres (large liquid volumes, holding tanks)
°C	Degrees Celsius (cook and fill temperatures)
°Brix	Brix refractometer readings (sugar concentration)
%	Percentage (acidity, viscosity tolerance)
bar	Pressure (capper, hot wash tunnel)
kPa	Pressure alternative unit
EA	Each (individual items, jars, cups)
CTN	Cartons

Go to Settings -> Configuration -> Unit of Measure -> Create

See Unit of Measure for details.

6

Create Material Groups

Material groups categorise your raw materials, semi-finished goods, and finished products. For a condiment factory:

Group	Description
Raw Materials	Fruits, vegetables, oils, vinegars, sugars, salt, spices
Ingredients	Flavourings, stabilisers, emulsifiers, preservatives, colours
Semi-Finished Goods	Cooked product ready for filling (bases, concentrates)
Finished Goods	Retail-packed glass jars (150 g – 300 mL)
Bulk	Large foodservice containers (2 kg – 10 kg)
PCL Packaging	Portion control cup packs (13 mL – 45 mL)
Glass	Glass jars by size
Caps	Lids and caps by type
Labels	Primary, secondary, and carton labels
Cartons	Outer cartons and outers
Lids	Press-on and screw lids for bulk containers
Plastic	Plastic cups and lids for PCL lines
Rework	Rework and returned product
WIP	Work-in-progress material

Go to Settings -> Material Definition -> Material Groups -> Create

See Material Group for details.

Separate Glass, Caps, Labels, and Cartons into their own groups to make it easier to track packaging consumption by type.

7

Add Materials

Materials represent the specific items consumed or produced during manufacturing. A condiment factory can have hundreds of materials across groups.

Raw Materials (sample)

• Produce - fresh tomatoes, onions, capsicum, cucumbers, fruit pulp

• Oils - canola oil, olive oil, sunflower oil

• Acids - white vinegar, apple cider vinegar, citric acid

• Sugar & Salt - white sugar, sea salt, glucose syrup

• Spices & Herbs - black pepper, garlic, mixed herbs, chilli flakes

Ingredients

• Emulsifiers - xanthan gum, guar gum, lecithin

• Preservatives - potassium sorbate, sodium benzoate

• Flavourings - lemon juice concentrate, garlic extract, herb blends

• Colours and modifiers - caramel colour, paprika extract

Semi-Finished Goods

Cooked product held in tanks ready for filling, typically named by product type:

• French Dressing Base

• Caesar Dressing Base

• Ranch Dressing Base

• Balsamic Vinaigrette Base

• BBQ Sauce Base

• Chilli Sauce Base

• Tomato Chutney Base

• Strawberry Jam Base

• Apricot Jam Base

Finished Goods (sample)

By format and product:

• Glass retail - e.g. "French Dressing 300 mL", "Ranch Dressing 300 mL", "BBQ Sauce 300 mL", "Apricot Jam 300 g"

• Bulk foodservice - e.g. "Caesar Dressing 2 kg", "Tomato Relish 2 kg", "Caramelised Onion 10 kg"

• Portion control cups - e.g. "Ranch Dressing 25 mL x 60", "BBQ Sauce 25 mL x 60", "Apricot Jam 14 g Cup x 120"

Go to Settings -> Material Definition -> Materials -> Create

For bulk loading, use the Excel Add-in to import materials from a spreadsheet.

See Material for details.

8

Define Attributes

Attributes store metadata against orders, materials, and assets. In condiment manufacturing, think of them as the product's digital "Product Specification Sheet" or identity card. They hold specific details that drive activity behaviour, store filling machine settings, and track label and packaging configurations per product. TilliT uses this information to automatically show or hide relevant fields based on that specific product type, as well as to help the Scheduler calculate changeover times.

Order Number Attributes

These attach to individual work orders. When orders are loaded via the API, attribute values are sent in the payload (see Step 14). Group them by purpose:

Product & Batch

Attribute	Data Type	Purpose
Batch	STRING	Batch number for traceability
Run	STRING	Production run identifier
Shelf Life	STRING	Shelf life in days or months

Label & Coding

Attribute	Data Type	Purpose
Label Date Coding - Format	STRING	Date code format printed on pack (e.g. DDMMYYYY)
Label Date Coding - Location	STRING	Position of date code on container
Print Message Primary Label	STRING	Text to print on the primary label
Print Message Inner Carton Label	STRING	Text to print on the inner carton
Print Message Outer Carton	STRING	Text to print on the outer carton label
Product EAN Barcode	STRING	EAN/GTIN barcode for the product
Carton TUN Barcode	STRING	Traded unit barcode for the carton
Carton Labeling Placement	STRING	Where carton labels are applied
Carton Dividers	STRING	Whether carton dividers are required
Carton Format	STRING	Carton configuration (e.g. 6pk, 12pk, tray)

Holding Tank Settings

Attribute	Data Type	Purpose
Holding Tank Temperature - Target	NUMBER	Target holding temperature (°C)
Holding Tank Temperature - Min	NUMBER	Minimum holding temperature (°C)
Holding Tank Temperature - Max	NUMBER	Maximum holding temperature (°C)
Holding Tank Stirrer Function	STRING	Stirrer speed or mode for this product

Filler Settings

Attribute	Data Type	Purpose
Fill Weight (g)	NUMBER	Target fill weight in grams
Fill Temperature Min	STRING	Minimum acceptable fill temperature
Fill Temperature Max	STRING	Maximum acceptable fill temperature
Filler Nozzles	STRING	Number and configuration of filler nozzles
Filler Speed	STRING	Filler speed setting
Forming Die Size (ml)	STRING	Die size for portion control lines
Forming Die Size Number of Turns	STRING	Adjustment turns for portion control die
Filling Program	STRING	Machine program number for this product

Capping & Sealing

Attribute	Data Type	Purpose
Sealing/Capping - Description	STRING	Cap or lid type description
Sealing/Capping - Integrity Test	STRING	Integrity test method (vacuum, pop test)
Sealing/Capping - Limits (bar/kPa) Min	NUMBER	Minimum acceptable cap pressure
Sealing/Capping - Limits (bar/kPa) Max	NUMBER	Maximum acceptable cap pressure

Washing & Sterilisation

Attribute	Data Type	Purpose
Hot Wash Tunnel Pressure	STRING	Hot wash tunnel pressure setting
Wash Tunnel Settings - Temperature	NUMBER	Hot wash tunnel temperature (°C)
Cooling Tunnel Program	STRING	Cooling tunnel program setting
Jar Prewarmer	STRING	Jar pre-warm setting (on/off, temperature)
UV Steriliser	STRING	UV steriliser enabled/mode
Crack Detection Unit	STRING	Crack detector setting
Cap Detection Unit	STRING	Cap presence detector setting
Break Detection Unit	STRING	Glass break detector setting
Air Dryer	STRING	Air dryer setting post-wash

Pallet Configuration

Attribute	Data Type	Purpose
Pallet Brand to Use	STRING	Pallet brand or type
Pallet Dividers	STRING	Whether pallet layer dividers are used
Pallet Divider Location	STRING	Where dividers are placed on the pallet
Pallet Wrap	STRING	Pallet wrap type
Pallet ID Sheet Requirements	STRING	Requirements for pallet identification sheet

Bin Tracking (portion control lines)

Attribute	Data Type	Purpose
Bins	NUMBER	Number of bins (PCL cups per cycle)
Bin 0 - Bin 12	STRING	Individual bin assignment tracking
Current Bin	NUMBER	Currently active bin index

Quality & Compliance

Attribute	Data Type	Purpose
Pre-Citrate Testing Required	STRING	Whether citrate testing is required before filling
Cleaning / Allergen Instructions	STRING	Specific cleaning or allergen changeover instructions
HasX-Ray	STRING	Whether X-ray inspection is in use
Other Instruction 1	STRING	General instructions for operators
Other Instruction 2	STRING	Additional instructions for operators

Go to Settings -> Configuration -> Attributes -> Create

See Attribute for details.

You do not need to create all attributes manually before loading orders. When you use the order upsert API (see Step 14), any attribute that does not already exist will be created automatically.

9

Set Up Process Variables

Process variables define the measurements operators capture during cooking and filling. They enforce quality spec limits per product.

Cook Quality (Kettles)

Process Variable	UoM	Purpose
Cook Limit	°C	Maximum cook temperature
Brix	°Brix	Sugar concentration (refractometer)
pH	--	Acidity measurement
Total Titratable Acidity (T.T.A)	%	Titratable acid content
Viscosity	--	Product viscosity check

Fill Quality (Glass Line & PCL)

Process Variable	UoM	Purpose
Fill Weight	g	Weight of each filled container
Fill Temperature	°C	Product temperature at the filler
Holding Tank Temperature	°C	Holding tank temperature at time of fill

Machine Monitoring

Process Variable	UoM	Purpose
Super Heated Steam Temperature	°C	Steam steriliser temperature
Cap Pressure	bar	Capper torque/pressure reading
Pop Pressure	bar	Vacuum pop test result (seal integrity)
Hot Wash Tunnel Tank Temperature	°C	Hot wash tunnel water temperature
Hot Wash Tunnel Pressure	bar	Hot wash tunnel pressure

Go to Settings -> Configuration -> Process Variable -> Create

See Process Variable for details.

Process variables (such as Brix or pH) can reference specific order attributes to automatically pull target values directly from the current work order. This ensures that a single activity template can dynamically adapt and work for all products.

10

Create Activity Classes

Activity classes group related activity templates in the UI. For a condiment factory:

Activity Class	Purpose
Cook Checks	Kettle startup, cook monitoring, pH and Brix testing
Prep Checks	Ingredient preparation and loading
Glass Line Checks	Filler startup, cap checks, label verification
PCL Checks	Portion control line startup, die setup, cup weight checks
Bulk Line Checks	Bulk filler setup, container checks
QA Checks	Finished product quality sign-offs
Data Capture	Consumption logs, wash tunnel logs, reconciliation
Cleaning	CIP and sanitisation logs
Safety	Safety guard and equipment checks
Downtime	Downtime reason capture

Go to Settings -> Activity Template -> Activity Classes -> Create

See Activity Class for details.

11

Build Activity Templates

Activity templates are the digital forms that operators interact with. A condiment factory typically has templates covering every stage from ingredient preparation through to palletised finished goods.

Core Activity Categories

Preparation & Cooking

Activity	Triggered by	Purpose
Prep Startup Check	Order start	Verify prep area is clean and ready
Ingredient Issuance	Order start	Record ingredients issued from store
Kettle Startup Check	Order start	Confirm kettle condition and settings
Cook Temperature Monitor	Interval	Record kettle temperature during cook
Brix Check	Interval	Record refractometer Brix reading
pH Check	Interval	Record pH measurement during cook
Total Titratable Acidity Check	Interval	Record T.T.A reading
Cook Completion Sign-off	Order end	Confirm cook meets spec, approve transfer
Ingredient Consumption	Order end	Record actual ingredient quantities used
Transfer to Holding Tank	Order end	Record volume transferred and tank used

Holding Tank Monitoring

Activity	Triggered by	Purpose
Holding Tank Level & Temperature	Interval	Monitor temperature and level in holding tanks
Holding Tank Reconciliation	Manual	Reconcile tank contents against production records

Glass Line

Activity	Triggered by	Purpose
Glass Line Startup Check	Order start	Line readiness: filler, capper, labeller settings
Label Verification	Order start	Confirm correct labels loaded for the product
Jar & Cap Information Record	Order start	Verify correct jar and cap sizes
Filler Settings Check	Order start	Confirm filler nozzles, speed, and program
Wash Tunnel Check	Order start	Verify wash tunnel temperatures and pressures
Fill Weight Check	Interval	Record fill weights against target
Fill Temperature Check	Interval	Record product temperature at filler head
Cap Pop Test	Interval	Verify vacuum seal integrity
Cap Pressure Check	Interval	Record capper pressure readings
Label Quality Check	Interval	Check label placement and date coding
Carton Check	Interval	Verify correct carton and overpacker settings
Glass Line End of Run	Order end	End-of-run reconciliation
Glass Line Downtime	Event-based	Record and categorise stoppages

Bulk Line

Activity	Triggered by	Purpose
Bulk Line Startup Check	Order start	Confirm bulk filler and container settings
Bulk Fill Weight Check	Interval	Record container weights
Bulk Line End of Run	Order end	Reconcile filled containers

Portion Control Lines

Activity	Triggered by	Purpose
PCL Startup Check	Order start	Die size, forming program, cup setup verification
PCL Cup Weight Check	Interval	Record individual cup fill weights
PCL Seal Integrity Check	Interval	Verify heat-seal quality
PCL End of Run	Order end	Record cup count and reconcile bins

Quality & Safety

Activity	Triggered by	Purpose
QA Sign-off	Order start / running	QA approval for starting or continuing a run
Pre-Citrate Testing	Event-based	Record pre-fill citrate test results
X-Ray Check	Shift start	Verify X-ray inspection equipment is operating
Safety Guard Check	Shift start	Confirm all safety guards are in place

Cleaning

Activity	Triggered by	Purpose
Pre-Production Cleaning Check	Shift start	Verify all equipment is clean before production
Kettle CIP Log	Event-based	Record kettle clean-in-place cycle
Glass Line CIP Log	Event-based	Record filling line CIP
Allergen Changeover Check	Event-based	Record allergen cleaning between different products
End of Day Cleaning	Shift end	Confirm end-of-day cleaning completed

Building an activity template

For each activity, you need to:

1. Create the template with a name and activity key

2. Assign it to an activity class

3. Set the "Claimable By" field to define who can see and claim the activity

4. Configure the trigger (when it fires)

5. Build the form items (the fields operators fill in)

Go to Settings -> Activity Templates -> Activity Template -> Create

See Creating an Activity for a complete walkthrough.

For understanding trigger types, see When and Where.

Start with the most critical activities - cook sign-off, fill weight checks, and cap integrity - and expand once the team is comfortable.

12

Configure Order Templates

Order templates define how a work order is executed across a bottling line. They specify which machines (child assets) within the bottling line (parent asset) participate in the order, as well as the operation type for each stage.

Preparation

Order Template	Operation	Asset
Prep	Prep	Prep Area

Cooking (one per kettle)

Order Template	Operation	Asset
Kettle 1	Cook	Kettle 1
Kettle 2	Cook	Kettle 2
Kettle 3	Cook	Kettle 3
Kettle 4	Cook	Kettle 4

Glass Line

The Glass Line uses a parent asset with child operations cascaded from it:

Order Template	Operation	From Asset	To Asset
Depalletiser	Depal	Glass Line	Depalletiser
Filler	Fill	Glass Line	Filler
Capper	Cap	Glass Line	Capper
Labeller	Label	Glass Line	Labeller
Carton Overpacker	Pack	Glass Line	Carton Overpacker
Palletiser	Pallet	Glass Line	Palletiser
QA	QA	Glass Line	QA

Bulk Line

Order Template	Operation	Asset
Bulk Line	Fill	Bulk Line

Portion Control Lines

Order Template	Operation	Asset
Portion Control Line 1	Fill	Portion Control Line 1
Portion Control Line 2	Fill	Portion Control Line 2

Key points

• Kettle orders are created independently for each cook. Cooked product is transferred to a holding tank on order completion.

• Glass Line orders are created against the Glass Line parent asset and automatically cascade to child equipment (Depalletiser, Filler, Capper, etc.).

• Bulk Line and PCL orders are standalone fill operations.

• QA is shared and configured as a child template under Glass Line.

Go to Settings -> Asset Hierarchy -> Order Templates -> Create

See Order Template for details.

13

Configure Edge Integration (Kepware OPC-UA)

TilliT Edge connects your factory equipment to TilliT Digital Operations in real time. This step walks through setting up a Kepware KEPServerEX demo environment with simulated tags, then connecting TilliT Edge to it via OPC-UA.

This guide uses Kepware's built-in Simulator driver to generate fake data without real PLC hardware. It is ideal for training, demos, and pre-go-live testing. Swap the simulated addresses for real PLC addresses when connecting live equipment.

1

Prerequisites

• Kepware KEPServerEX installed (v6.x or later) with the Simulator driver licensed

• Kepware's OPC-UA Server interface enabled (included by default)

• TilliT Edge Core software installed on a Windows machine on the same network as Kepware

• Firewall allows inbound TCP on port 49320 (Kepware OPC-UA default)

2

Create the Kepware Channel and Devices

Open KEPServerEX Configuration. In the left-hand project tree under Connectivity, create the following structure:

Add Channel

Field	Value
Channel Name	SauceFactory
Device Driver	Simulator
Communications	Leave defaults

Add Devices under SauceFactory:

Device Name	Description
Kettles	Cooking kettle signals
HoldingTanks	Holding tank temperatures and levels
GlassLine	Glass bottle line signals
BulkLine	Bulk filling line signals
PortionControl	Portion control line signals

For each device, accept the Simulator driver defaults (Device ID = 1, scan rate = 100 ms).

3

Create Simulated Tags

Add the following tags to each device. In Kepware's Simulator driver, R registers are read-only and auto-ramp continuously from 0 to 32,767 — ideal for simulating changing analog values without real hardware. K registers are read/write integers; individual bits (e.g. K0000.0) simulate boolean signals that can be toggled manually in the Quick Client.

Device: Kettles

Tag Name	Address	Data Type	Notes
Kettle1_Temperature	R0000	Word	Ramps 0–32767; apply scale ×0.003 in TilliT → 0–98 °C
Kettle1_Status	K0000.0	Boolean	True = running
Kettle2_Temperature	R0001	Word	Same scaling
Kettle2_Status	K0000.1	Boolean	True = running
Kettle3_Temperature	R0002	Word
Kettle3_Status	K0000.2	Boolean
Kettle4_Temperature	R0003	Word
Kettle4_Status	K0000.3	Boolean

Device: HoldingTanks

Tag Name	Address	Data Type	Notes
Tank1_Temperature	R0010	Word	Scale ×0.003 → 0–98 °C
Tank1_Level	R0011	Word	Scale ×0.003 → 0–98 %
Tank2_Temperature	R0012	Word
Tank2_Level	R0013	Word
Tank3_Temperature	R0014	Word
Tank3_Level	R0015	Word
Tank4_Temperature	R0016	Word
Tank4_Level	R0017	Word

Device: GlassLine

Tag Name	Address	Data Type	Notes
GlassLine_Status	K0001.0	Boolean	True = running
GlassLine_ProductionCount	R0020	Word	Auto-incrementing counter
Filler_FillWeight	R0021	Word	Scale ×0.01 → 0–327 g
Filler_FillTemperature	R0022	Word	Scale ×0.003 → 0–98 °C
Capper_CapPressure	R0023	Word	Scale ×0.00002 → 0–0.65 bar

Device: BulkLine

Tag Name	Address	Data Type	Notes
BulkLine_Status	K0002.0	Boolean	True = running
BulkLine_ProductionCount	R0030	Word	Auto-incrementing counter

Device: PortionControl

Tag Name	Address	Data Type	Notes
PCL1_Status	K0003.0	Boolean	True = running
PCL1_CupCount	R0040	Word	Auto-incrementing counter
PCL2_Status	K0003.1	Boolean	True = running
PCL2_CupCount	R0041	Word	Auto-incrementing counter

After adding all tags, click File → Save in KEPServerEX. The runtime hot-deploys tag changes immediately.

To verify tags are reading, open the Quick Client (Tools → Launch Quick Client) and browse to SauceFactory. R register values will be incrementing every scan cycle. Toggle K register bits to simulate equipment status changes.

4

Confirm Kepware OPC-UA Server Settings

Go to Tools → Options → Runtime Process in KEPServerEX, then select OPC-UA from the left panel.

Setting	Value
Enable OPC-UA Server Interface	✓ Checked
Endpoint Port	49320
Allow Anonymous Login	✓ Checked (demo purposes)

Click Apply, then reinitialise the runtime if prompted (Runtime → Reinitialize).

The OPC-UA endpoint will be: opc.tcp://<kepware-host-ip>:49320

All tags are addressable via OPC-UA node IDs using this format:

ns=2;s=SauceFactory.<DeviceName>.<TagName>

For example, Kettle1_Temperature is:

ns=2;s=SauceFactory.Kettles.Kettle1_Temperature

5

Create a TilliT Edge

Go to Settings -> Edge -> Edges -> Create

Field	Value
Name	Sauce Factory Edge
Type	Core
Description	Edge agent for Kepware OPC-UA simulation

Save, then install and start the TilliT Edge Core service on the Windows machine running Kepware. See Edge for installation instructions.

6

Create the OPC-UA Data Source

Go to Settings -> Edge -> Data Sources -> Create

Field	Value
Name	Kepware Simulator
Edge	Sauce Factory Edge
Datasource Type	OPC_UA
Endpoint	<kepware-host-ip>:49320
Option	{"securityMode":1,"securityPolicy":"http://opcfoundation.org/UA/SecurityPolicy#None"}

The securityMode: 1 option disables encryption — appropriate for a local demo network. For production, use securityMode: 3 with Basic256Sha256 and trust the TilliT Edge certificate in Kepware's OPC-UA Security settings.

Press Publish Configuration and wait for the connected status to show a green checkmark (updates every 60 seconds).

See Common Data Sources for details.

7

Create Data Tags

Go to Settings -> Edge -> Data Tags -> Create

Map each Kepware tag to a TilliT asset and, where applicable, a process variable. The scale option in the Options field adjusts the raw 0–32,767 Word value to a physically meaningful range.

Kettle temperatures

Name	Asset	Source Address	Data Type	Process Variable	Options
Kettle 1 Temperature	Kettle 1	ns=2;s=SauceFactory.Kettles.Kettle1_Temperature	Number	Cook Limit	{"scale":0.003}
Kettle 2 Temperature	Kettle 2	ns=2;s=SauceFactory.Kettles.Kettle2_Temperature	Number	Cook Limit	{"scale":0.003}
Kettle 3 Temperature	Kettle 3	ns=2;s=SauceFactory.Kettles.Kettle3_Temperature	Number	Cook Limit	{"scale":0.003}
Kettle 4 Temperature	Kettle 4	ns=2;s=SauceFactory.Kettles.Kettle4_Temperature	Number	Cook Limit	{"scale":0.003}

Kettle status

Name	Asset	Source Address	Data Type	Template
Kettle 1 Status	Kettle 1	ns=2;s=SauceFactory.Kettles.Kettle1_Status	Boolean	EQUIPMENT_STATUS_RUNNING
Kettle 2 Status	Kettle 2	ns=2;s=SauceFactory.Kettles.Kettle2_Status	Boolean	EQUIPMENT_STATUS_RUNNING
Kettle 3 Status	Kettle 3	ns=2;s=SauceFactory.Kettles.Kettle3_Status	Boolean	EQUIPMENT_STATUS_RUNNING
Kettle 4 Status	Kettle 4	ns=2;s=SauceFactory.Kettles.Kettle4_Status	Boolean	EQUIPMENT_STATUS_RUNNING

Holding tank monitoring

Name	Asset	Source Address	Data Type	Process Variable	Options
Holding Tank 1 Temperature	Holding Tank 1	ns=2;s=SauceFactory.HoldingTanks.Tank1_Temperature	Number	Holding Tank Temperature	{"scale":0.003}
Holding Tank 1 Level	Holding Tank 1	ns=2;s=SauceFactory.HoldingTanks.Tank1_Level	Number	--	{"scale":0.003}
Holding Tank 2 Temperature	Holding Tank 2	ns=2;s=SauceFactory.HoldingTanks.Tank2_Temperature	Number	Holding Tank Temperature	{"scale":0.003}
Holding Tank 2 Level	Holding Tank 2	ns=2;s=SauceFactory.HoldingTanks.Tank2_Level	Number	--	{"scale":0.003}
Holding Tank 3 Temperature	Holding Tank 3	ns=2;s=SauceFactory.HoldingTanks.Tank3_Temperature	Number	Holding Tank Temperature	{"scale":0.003}
Holding Tank 3 Level	Holding Tank 3	ns=2;s=SauceFactory.HoldingTanks.Tank3_Level	Number	--	{"scale":0.003}
Holding Tank 4 Temperature	Holding Tank 4	ns=2;s=SauceFactory.HoldingTanks.Tank4_Temperature	Number	Holding Tank Temperature	{"scale":0.003}
Holding Tank 4 Level	Holding Tank 4	ns=2;s=SauceFactory.HoldingTanks.Tank4_Level	Number	--	{"scale":0.003}

Glass Line

Name	Asset	Source Address	Data Type	Template / PV	Options
Glass Line Status	Filler	ns=2;s=SauceFactory.GlassLine.GlassLine_Status	Boolean	EQUIPMENT_STATUS_RUNNING	--
Glass Line Production Count	Filler	ns=2;s=SauceFactory.GlassLine.GlassLine_ProductionCount	Number	COUNT_TOTAL	--
Fill Weight	Filler	ns=2;s=SauceFactory.GlassLine.Filler_FillWeight	Number	Fill Weight	{"scale":0.01}
Fill Temperature	Filler	ns=2;s=SauceFactory.GlassLine.Filler_FillTemperature	Number	Fill Temperature	{"scale":0.003}
Cap Pressure	Capper	ns=2;s=SauceFactory.GlassLine.Capper_CapPressure	Number	Cap Pressure	{"scale":0.00002}

Bulk Line and Portion Control Lines

Name	Asset	Source Address	Data Type	Template / PV
Bulk Line Status	Bulk Line	ns=2;s=SauceFactory.BulkLine.BulkLine_Status	Boolean	EQUIPMENT_STATUS_RUNNING
Bulk Line Production Count	Bulk Line	ns=2;s=SauceFactory.BulkLine.BulkLine_ProductionCount	Number	COUNT_TOTAL
PCL 1 Status	Portion Control Line 1	ns=2;s=SauceFactory.PortionControl.PCL1_Status	Boolean	EQUIPMENT_STATUS_RUNNING
PCL 1 Cup Count	Portion Control Line 1	ns=2;s=SauceFactory.PortionControl.PCL1_CupCount	Number	COUNT_TOTAL
PCL 2 Status	Portion Control Line 2	ns=2;s=SauceFactory.PortionControl.PCL2_Status	Boolean	EQUIPMENT_STATUS_RUNNING
PCL 2 Cup Count	Portion Control Line 2	ns=2;s=SauceFactory.PortionControl.PCL2_CupCount	Number	COUNT_TOTAL

Press Publish Configuration after creating all tags. Tags with a green status indicator are reading successfully from Kepware.

See Data Tags for details.

8

Create Edge Triggers (Optional)

Edge triggers raise TilliT events automatically based on tag values. For a condiment factory, the most useful triggers are equipment stopped events and temperature alarms.

Go to Settings -> Edge -> Triggers -> Create

Trigger	Tag	Event Type	Evaluation Script	Self Close
Kettle 1 Stopped	Kettle 1 Status	Equipment Stopped	value == false	Yes
Kettle 2 Stopped	Kettle 2 Status	Equipment Stopped	value == false	Yes
Glass Line Stopped	Glass Line Status	Equipment Stopped	value == false	Yes
Kettle Overtemp	Kettle 1 Temperature	Custom Alert	value > 90	Yes

Set Minimum Duration to 1 minute on the equipment stopped triggers to avoid spurious events from brief signal interruptions.

See Edge Triggers for details.

14

Integrate Order Loading from ERP

In most condiment factories, work orders originate in an ERP system (SAP, MYOB, Microsoft BC, etc.) and need to flow into TilliT automatically. Use the POST:/core/order-instances/upsert endpoint to load orders with all their attributes, tolerances, and components.

Order Payload Structure

The upsert endpoint accepts an array of orders. Each order carries the core fields plus arrays for attributes, tolerances, and components. Below is an example glass line order for a retail dressing:

[
  {
    "orderNumber": "WO-20260101-001",
    "orderDate": "2026-01-01",
    "dueDate": "2026-01-02",
    "scheduledStart": "2026-01-02T06:00:00",
    "scheduledEnd": "2026-01-02T14:00:00",
    "quantityTarget": 3600,
    "defaultRunRate": 60,
    "status": "NEW",
    "name": "French Dressing 300mL",
    "asset": "Glass Line",
    "material": {
      "externalId": "FG-FRENCH-300",
      "name": "French Dressing 300mL"
    },
    "attributes": [
      { "attributeName": "Batch", "value": "BT-20260102-001" },
      { "attributeName": "Shelf Life", "value": "365" },
      { "attributeName": "Label Date Coding - Format", "value": "DDMMYYYY" },
      { "attributeName": "Label Date Coding - Location", "value": "Cap" },
      { "attributeName": "Print Message Primary Label", "value": "Best Before: " },
      { "attributeName": "Print Message Outer Carton", "value": "French Dressing 12x300mL" },
      { "attributeName": "Product EAN Barcode", "value": "9300001000001" },
      { "attributeName": "Carton TUN Barcode", "value": "09300001000001" },
      { "attributeName": "Carton Format", "value": "12pk" },
      { "attributeName": "Carton Dividers", "value": "No" },
      { "attributeName": "Holding Tank Temperature - Target", "value": "75" },
      { "attributeName": "Holding Tank Temperature - Min", "value": "70" },
      { "attributeName": "Holding Tank Temperature - Max", "value": "80" },
      { "attributeName": "Holding Tank Stirrer Function", "value": "Low" },
      { "attributeName": "Fill Weight (g)", "value": "310" },
      { "attributeName": "Fill Temperature Min", "value": "70" },
      { "attributeName": "Fill Temperature Max", "value": "80" },
      { "attributeName": "Filler Speed", "value": "60" },
      { "attributeName": "Filling Program", "value": "P12" },
      { "attributeName": "Sealing/Capping - Description", "value": "Twist Cap 63mm" },
      { "attributeName": "Sealing/Capping - Integrity Test", "value": "Pop Test" },
      { "attributeName": "Sealing/Capping - Limits (bar/kPa) Min", "value": "0.2" },
      { "attributeName": "Sealing/Capping - Limits (bar/kPa) Max", "value": "0.5" },
      { "attributeName": "Wash Tunnel Settings - Temperature", "value": "85" },
      { "attributeName": "Jar Prewarmer", "value": "On" },
      { "attributeName": "UV Steriliser", "value": "On" },
      { "attributeName": "Crack Detection Unit", "value": "Active" },
      { "attributeName": "Pallet Brand to Use", "value": "Standard CHEP" },
      { "attributeName": "Pallet Wrap", "value": "Yes" },
      { "attributeName": "Cleaning / Allergen Instructions", "value": "Allergen free - standard rinse" }
    ],
    "tolerances": [
      { "processVariableName": "Fill Weight", "target": 310, "lowerLimit": 305, "upperLimit": 315 },
      { "processVariableName": "Fill Temperature", "target": 75, "lowerLimit": 70, "upperLimit": 80 },
      { "processVariableName": "Brix", "target": 18.0, "lowerLimit": 17.0, "upperLimit": 19.0 },
      { "processVariableName": "pH", "target": 3.8, "lowerLimit": 3.5, "upperLimit": 4.1 }
    ],
    "orderComponents": [
      { "componentExternalId": "SFG-FRENCH-BASE", "componentGroup": "Semi-Finished Goods", "componentName": "French Dressing Base", "target": 1100 },
      { "componentExternalId": "PKG-GLS-300-FRENCH", "componentGroup": "Glass", "componentName": "300mL Jar", "target": 3700 },
      { "componentExternalId": "PKG-CAP-63-TWIST", "componentGroup": "Caps", "componentName": "63mm Twist Cap", "target": 3700 },
      { "componentExternalId": "PKG-LAB-FRENCH-300", "componentGroup": "Labels", "componentName": "French Dressing 300mL Label", "target": 3700 },
      { "componentExternalId": "PKG-CTN-12PK-300", "componentGroup": "Cartons", "componentName": "12pk Outer Carton", "target": 310 }
    ]
  }
]

Key points

• asset - set to the parent line name (e.g. Glass Line). If order templates are configured (Step 12), the order will automatically cascade to child assets (Depalletiser, Filler, Capper, etc.).

• attributes - all values are strings, even for NUMBER types. TilliT converts them based on the attribute definition.

• tolerances - override default process variable limits for this specific product. Only include tolerances that differ from the defaults.

• orderComponents - the bill of materials. Include the semi-finished base plus packaging components.

• Upsert behaviour - if you send a work order that matches an existing combination of orderNumber, operation, and asset, TilliT will simply update the details instead of creating a duplicate. This allows you to safely re-send or refresh the full schedule whenever it changes.

• Auto-creation - materials, attributes, UoMs, and tolerances that do not already exist will be created automatically.

Typical attribute categories in the payload

Category	Attributes	Purpose
Traceability	Batch, Run, Shelf Life	Batch control and date management
Label & coding	Label Date Coding, Print Messages, Barcodes, Carton Format	Correct labelling and coding per SKU
Holding tank	Temperature Target/Min/Max, Stirrer Function	Product held at correct temperature before filling
Filler settings	Fill Weight, Fill Temperature, Filler Speed, Filling Program	Machine configuration per product
Capper settings	Sealing Description, Integrity Test, Pressure limits	Cap application and seal verification
Wash & sterilise	Wash Tunnel Temperature, Jar Prewarmer, UV Steriliser	Hygiene and glass preparation
Detection	Crack Detection, Cap Detection, Break Detection	Online quality inspection
Pallet	Pallet Brand, Pallet Wrap, Dividers	Palletising configuration
Cleaning	Allergen Instructions	Changeover cleaning requirements

For the full API reference, see Upload Production Schedule.

15

Create Your First Work Order

With all master data in place, you can test by creating a work order manually:

1. Navigate to the line where you want to run the order (e.g. Glass Line)

2. Click Create Order

3. Select the material (finished good) to produce (e.g. French Dressing 300 mL)

4. Enter the quantity

5. Fill in the order number attributes (holding tank settings, filler program, label coding)

6. Start the order

When the order starts, TilliT will automatically trigger the configured activities (glass line startup check, label verification, filler settings check) and the order will flow through each machine according to the order template.

See Create adhoc Order and Start an Order for details.

16

Verify Live Edge Data

With an order running and the Kepware simulator active, confirm that edge data is flowing correctly end-to-end.

1. Open the Glass Line asset in TilliT

2. Confirm the Equipment Status indicator shows running (driven by GlassLine_Status)

3. Navigate to Process Variables and verify Fill Weight and Fill Temperature are updating every minute from the simulated Kepware tags

4. In Kepware's Quick Client, toggle GlassLine_Status (K0001.0) to false - TilliT should raise a Glass Line Stopped event within the trigger's minimum duration

5. Toggle the status back to true - the event should self-close

6. Check the Production Count on the Filler asset is incrementing as the R0020 register ramps

If any tags show a red status in Settings -> Edge -> Data Tags, press Publish Configuration on the data source and verify the Kepware OPC-UA server is reachable from the TilliT Edge host.

See Data Tags for troubleshooting guidance.

Summary Checklist

Use this checklist to track your progress:

• Site created with correct timezone

• Asset classes defined (Area, Preppers, Kettles, Tanks, Depalletisers, Fillers, Cappers, Labellers, Packers, Palletisers)

• Assets created with correct parent-child hierarchy (Prepping & Cooking, Glass Line, Bulk Line, PCL lines, QA)

• Shift templates configured (Day Shift, Afternoon Shift)

• Units of measure defined (g, kg, mL, L, °C, °Brix, %, bar, EA, CTN)

• Material groups created (Raw Materials, Ingredients, Semi-Finished Goods, Finished Goods, Bulk, PCL Packaging, Glass, Caps, Labels, Cartons)

• Materials loaded (ingredients, bases, packaging, finished goods by format)

• Attributes defined (batch/label, holding tank, filler, capper, wash tunnel, pallet)

• Process variables configured (Brix, pH, T.T.A, Fill Weight, Fill Temperature, Cap Pressure)

• Activity classes created

• Activity templates built and triggers configured (cook, fill, cap, label, QA, cleaning)

• Order templates mapped (Prep, Kettle 1-4, Glass Line, Bulk Line, PCL 1, PCL 2)

• Kepware channel SauceFactory created with Simulator driver

• Simulated tags created for Kettles, HoldingTanks, GlassLine, BulkLine, PortionControl devices

• Kepware OPC-UA server enabled on port 49320

• TilliT Edge (Core) installed and running

• OPC-UA data source configured and connected (green status)

• Data tags created and publishing to correct assets and process variables

• Edge triggers configured (equipment stopped, overtemp)

• Order integration configured and payload tested

• First work order tested end-to-end with live edge data verified

Related Articles

• Planning Overview

• Data Gathering Checklist

• Upload Production Schedule (API)

• Edge Overview

• Common Data Sources

• Data Tags

• Entity Data Source