More Than Just a PLC: How Opto 22 Optimizes Water Treatment Plants

Transforming Water Utility Operations With Intelligent Automation and Remote Control

Modern water utilities face growing challenges: improving efficiency, reducing operating costs, maintaining compliance, and ensuring reliable service delivery. The control systems running treatment and distribution infrastructure must be powerful, flexible, and secure — not limited to basic input/output functions.

Opto 22’s EPIC and RIO platforms deliver an all-in-one PLC and industrial Linux computer designed specifically for critical infrastructure, enabling water treatment plants to automate, optimize, and remotely manage operations like never before.

What Makes Opto 22 Different

Traditional PLCs simply move signals in and out. Opto 22 goes far beyond, integrating real-time process control, industrial computing power, high-speed data handling, remote visualization, and cybersecurity into a single device.

Key Advantages

• All-in-one PLC + industrial computer

• Real-time process automation & optimization

• Local high-speed data storage and logging

• Secure remote access from anywhere

• Custom dashboards and visualization tools

• Designed for water treatment and distribution applications

This allows utilities to analyze performance instantly, react faster to operational changes, and implement modern automation without unnecessary external hardware.

Easy Programming Options

Opto 22 gives operators and engineers freedom to work in the way that suits them best. The system supports:

• Process-flow visual programming — operator-friendly with no complex coding

• C++ for advanced engineering logic

• Python scripting for automation, analytics, and reporting integration

This flexibility reduces reliance on third-party programmers and allows internal utility staff to maintain and enhance automation over time.

Built-In Cybersecurity

Infrastructure cybersecurity is a top priority for water utilities. Opto 22 strengthens protection with:

• Hardened Linux operating system

• User access control and network firewalling

• Encrypted communications

• No Windows-based vulnerabilities

This minimizes cyber-intrusion risk across water systems, pump stations, PRVs, and SCADA networks.

Custom HMI Interface for Any Device

With Opto 22, utilities can build custom dashboards for:
📱 Smartphones
📲 Tablets
💻 Laptops
🖥️ Control room screens

Operators can monitor alarms, analyze flows, view pump and UV system performance, and adjust process setpoints remotely and securely — improving reliability and reducing operational cost.

Case Study: Transforming a Rural Water Treatment Plant

Project Overview

A rural water co-op was using outdated PLC hardware with limited visibility and no remote access. Operators were required to physically travel to the plant for alarms or adjustments, causing response delays and unnecessary call-out hours.

Challenges Before Opto 22

• No remote monitoring or alarm access

• Manual reporting and paper-based records

• 6–8 after-hours callouts per month

• Fragmented, outdated equipment

• Limited cybersecurity controls

The Opto 22 Upgrade Solution

• Installed Opto 22 EPIC all-in-one automation platform

• Implemented secure mobile remote access

• Built custom HMI dashboards accessible from phones and tablets

• Combined process flow automation + Python analytics

• Enabled automated data logging & reporting

Visual KPI Overview

Measured performance improvements after upgrading to an Opto 22 EPIC platform (Crion Group case study).

The Future of Water Utility Automation

Opto 22 enables utilities to adopt:

• Smart pressure & pump optimization

• Energy-usage analytics

• Modern SCADA integration

• Remote operational staffing

• Predictive maintenance

• Cloud and AI compatibility

Opto 22 is more than a PLC — it’s a scalable automation platform that improves performance, reliability, and efficiency across water treatment and distribution systems.