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BLUECTRL: an edge platform for modular industrial plants

Control and digitalisation platform of BLUELINE / Linetechnology GmbH for modular recycling plants at different customer sites. From the controller to the cloud, offline-capable and updated over the air.

Architecture at a glanceat the plantplatform and pipeline
Data
  1. ControllerPLC
  2. Python serviceOPC UA
  3. RabbitMQAMQP
  4. Telegraf
  5. InfluxDBtime series
  6. Grafanadashboards
Updates
  1. GitLab CImulti-arch builds
  2. MenderOTA
  3. Edge deviceRevolution Pi
Operations
  1. Promtail, Node Exporterlogs, metrics
  2. Lokilogs
  3. Grafanaalerts

TimescaleDB is planned as the successor to InfluxDB.

Starting point

The plants consist of modules that are installed at customer sites in different locations. The modules include controllers and edge devices. Customer networks are isolated and connectivity is not guaranteed. Still, every module has to be monitored, configured and updated without sending anyone on site.

Architecture

Machine data

A Python service on the edge device reads the controller values via OPC UA. Messages flow through AMQP (RabbitMQ), Telegraf writes them to the time-series database InfluxDB, and Grafana displays them. A migration to TimescaleDB is planned.

Edge fleet

The edge devices are Revolution Pi units with embedded Linux, the software runs in containers. The modules keep working offline. Every device has its own identity with keys, serial number and provisioning.

Updates

Operating system and software stack are updated with Mender OTA, without site visits. GitLab CI builds multi-arch images, including ARM, and takes every version from commit to device. A fleet management system tracks inventory, configuration and lifecycle of the devices.

Monitoring

Logs go via Promtail to Loki, metrics from selected devices via Node Exporter. Grafana monitors the distributed systems across sites and raises alerts.

Operations and cloud exit

The server side originally ran on Azure PaaS services and was moved to self-operated containers at Hetzner. This was possible because the edge devices work offline, which makes the cloud replaceable.

Operation

An offline-capable Angular PWA runs on a tablet right at the plant for setup, configuration and commissioning. It talks to the edge services in real time over WebSockets and copes with dropped connections. In 2026 the app was migrated from Angular 16 to Angular 22.

Who did what

Thomas Deutsch has been employed at BLUELINE / Linetechnology as Lead Industrial IoT & Platform Architect since 2024 and is responsible for architecture, development and operations of BLUECTRL. Most of the platform described here was built in that role.

CFE-Computing GmbH supports the operation of the plant control system as an external partner and provided technical guidance for the migration of the operator app to Angular 22 in 2026.

BLUECTRL is a reference from the team's own practice. The chain reaches from the controller to the user interface and runs in the field.

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Get in touch

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