/ Castle & Key /

Project Overview

Castle & Key partnered with Gray AES to implement a high-performance SCADA system using Ignition by Inductive Automation.

This collaboration modernized Castle & Key’s automation environment, improved access to historical data, and elevated operator efficiency—all while supporting the heritage of a site that dates back to the 1890s.

Challenge

Castle & Key’s previous SCADA system lacked critical historical data, limiting their ability to forecast production needs for spirits that require years to mature. Additionally, the aging FactoryTalk platform created inefficiencies for operators working in a fast-paced, highly regulated environment that needed to balance tradition with technical advancement.

Gray AES Solution

Seamless SCADA Upgrade

Gray AES replaced the legacy FactoryTalk system with Ignition's mobile-responsive Perspective Module. This transformation included:

• A new SCADA system with a high-performance HMI tailored for iPad use

• A modern interface using CSS and style sheets for an intuitive operator experience

• A DevOps-driven deployment process leveraging Docker and GitHub for agile development

The implementation was conducted in parallel with ongoing production to avoid downtime. By running the new and old systems simultaneously, Castle & Key maintained full operations during the transition.

Data-Driven Performance

Using Ignition’s Tag Historian Module and Alarm Notification Module, Gray AES enabled:

• Comprehensive access to real-time and historical data

• Enhanced trend analysis and anomaly detection

• Remote monitoring and faster alarm response times

Castle & Key now uses this data to correlate sensory product evaluations with production metrics, bringing scientific precision to the art of whiskey making.

Operator-Centered Design

Incorporating feedback from the plant floor, Gray AES customized the HMI design to:

• Reflect the operators’ preferred teal color background

• Preserve intuitive interaction using custom-built momentary push buttons

• Offer mobility and responsive screen navigation for field use

This inclusive approach empowered Castle & Key’s staff to feel invested in the new system and improved adoption across teams.

Results

• Zero production downtime during deployment

• Increased operational efficiency and accuracy

• Access to over 27,000 live tags and 736 alarms

• Streamlined interface across 27 screens and 16 popups

• Improved ability to align product strategy with data-driven insights

As Castle & Key continues to grow, their Ignition platform—implemented and supported by Gray AES—positions them to scale while remaining true to their brand identity and craftsmanship.

Project Highlights

• Industry: Distilled Spirits / Beverage Manufacturing

• Location: Frankfort, Kentucky

• Tags Created: 27,505

• Screens Designed: 27

• Pop-ups: 16

• Historical Tags Logged: 62

• Clients Supported: 10

• System Architecture: 1 Ignition Gateway, 1 Database, 1 Device

Partnering for Progress

Gray AES is proud to support Castle & Key with innovative engineering, automation, and integration solutions that honor Kentucky’s legacy while shaping its future. As our shared journey continues, this project stands as a model for blending tradition with digital transformation in the distilled spirits industry.