Dorset Group Transforms Raw Drying‑System Data into Optimized Processes

Monitoring and aggregating raw data from our drying systems via the IXON Cloud API gives us proactive service capabilities and deeper sales insights.

Dorset Group is a trusted supplier and manufacturer of air‑cleaning systems, RFID solutions, and the market leader in biomass drying. Our “Green Machines” convert agricultural waste and manure into bio‑material—such as granules—while capturing residual heat for energy. This approach keeps energy consumption low and significantly reduces dust emissions on farms and livestock facilities.

The decision to collect system data proved to be a strategic win and aligns with Dorset’s commitment to continuous innovation.

Digestate dryer from Dorset Group

“Providing global support was already part of our service package, covering both remote control and remote software troubleshooting,” says Chris Lam, Data Engineer at Dorset Group. Because of the data requirements, we chose IXON Cloud.

IXON delivers a single platform for remote access and data monitoring—fast, stable, and future‑proof.

Chris’s first project was to generate actionable insights for our sales and customer‑support teams. “Initially we monitor and control new installations. Later we collect raw data for analysis and cross‑system comparison,” he explains.

We expose the Siemens PLC’s raw data—sensor measurements, downtime, alarm fault codes—on the IXON Cloud via IXrouter.

Chris built a Power BI prototype to retrieve historical data and compare systems. “Through the IXON API we pull all system data, store it centrally in a local SQL database, and import it daily into Power BI with a Python script,” he says.

The goal is to resolve faults proactively and provide instant access to every field unit.

Dorset Digestate drying equipment in container

“Our service team uses these insights to react proactively and fix faults before they become critical. Sales leverages the data to demonstrate ROI,” Chris notes. We’re also building a comprehensive history of every system so that engineers can continuously refine product and process efficiency.

Each new dryer comes with two years of data monitoring. We deliver three standard dashboards—also accessible to customers through our IXON portal. After the initial period, customers can opt to extend monitoring. Because most systems are identical, we use IXON’s templates and import/export features to configure everything quickly.

Custom dashboards for new installations take no more than half an hour. We update our Excel sheet, import the new data tags, and load the dashboards into the IXON portal.

Historical dashboard of a Dorset dryer in Germany – IXON

Integrating Connectivity Devices from Multiple Suppliers in One Portal

The move to IXON’s remote‑access platform initially created confusion in the service department. “With hundreds of field units, it was unclear which customers had an IXrouter, so the team had to search through two systems,” Chris says.

To solve this, he developed the “Dorset Connect” portal, automatically aggregating all IXrouters and the current install base. The Node.js project is publicly available on GitHub, enabling anyone to reuse the code.

“With Dorset Connect we can search for all customer systems and launch a direct VNC or remote‑desktop link with a single click. The customer dashboards open instantly in the IXON platform,” he explains.

The IXON API is robust, though it does require some web‑tech knowledge.

Live dashboard with real‑time data from a Dorset installation in Germany – IXON

As customer demand for monitoring grows, Dorset stays ahead of the competition. Power BI will soon integrate with Office 365 and Microsoft Teams, and will also embed into the Dorset Connect portal. “We aim to make dashboards accessible for every process,” says Chris.

Want to learn how customers benefit from machine data or the IXON API? Explore our customer stories or contact an expert for a demo or meeting.

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