About noosa* yoghurt
Founded in 2010 and named after a town in Queensland, Australia,
noosa yoghurt was created to bring quality Aussie-style yogurt to theUnited States. Based in Bellvue, Colorado, the company was built on
an authentic Australian family recipe and has a strong dedication todelivering a quality food product to yogurt consumers in new anddifferent ways. These qualities have allowed the company to become adominant force within the flourishing yogurt industry.
noosa yoghurt has introduced more than two dozen varieties of yogurt
to the U.S. market. The yogurt is made with whole milk and wildflower
honey from local, family-owned producers in and near Bellvue, Colorado.
noosa yoghurt was acquired by a private equity firm in 2014, whichallows the company to build out its plan for future capacity. With all
13 flavors available in 50 states and Puerto Rico, noosa yoghurt isdistributed nationally to over 5,000 retailers in 25,000 stores, including
Safeway, Whole Foods Market, Kroger, and Target.

Companynoosa yoghurt

Country
United States

Industry
Food & Beverage

Business Challenges
Deliver a highly available, reliablenetwork infrastructure to accommodate
rising production demands, decrease
downtime, and promote productstandardization.

Panduit ONESM Partners
Malisko Engineering, Inc.
Piper Communication Services, Inc.

Panduit Solution
A simplified robust industrial network
and Industrial Internet of Things (IIoT)
deployment that includes the Integrated
Network Zone System, Pre-Configured
Industrial Micro Data Center, PreConfigured Industrial Distribution Frame,
multimode fiber cabling, and Category
6A/6 copper cabling.

Business Benefits
A reliable, end-to-end network physicallayer infrastructure that enables
communications between the controlroom and manufacturing floor, providing
high availability, scalability, and reduced
deployment time by up to 75%.
Standardized pre-configured equipment
for consistency and quick deployment,
providing 25% faster implementation thana non-pre-configured solution.

Upgrading a Manufacturing Plant to Meet
Production Demands
Panduit® ecosystem helps noosa* yoghurt speed production
at maximum efficiency while increasing network reliability
and productivity

Business Challenges
noosa yoghurt’s commitment to making a superior product propelled thecompany to invest in a $5 million plant upgrade that was completed in 2015. Thisproject allowed noosa yoghurt to increase production and nationwide awarenessof the brand while remaining a leader of current dairy and food trends.
As the original plant (built in 2012) increased production, a small, standalone
industrial network grew organically as product demand surged. As the network
grew without standardized methods, it became cumbersome to troubleshoot,often resulting in costly unscheduled downtime.
Documentation of the plant’s physical network infrastructure was minimal, and as
cable rerouting and building designs changed, it was clear that the old network
could not support the expansion because it lacked the inherent scalability of
today’s future-ready industrial networks.
As a greenfield installation for the expansion, a standardized design would allow
noosa yoghurt to work on different cells, one zone at a time, without affecting
production uptime. In addition, the zone placements could be broken up byfunctional areas, complementing a future-ready, segmented logical design.
With both enterprise and plant floor network workstations in the same locations
throughout the plant, the company also needed to assure a clear demarcation
between enterprise and manufacturing zone network resources. This would allow
these critical networks to coexist without adversely affecting one another in thecase of a network event.

“We needed a new design that would allow
us to work on different cells without affecting
production. This will result in future costsavings while decreasing downtime.”
Rob Graves
Co-Founder, noosa yoghurt

2Strategic Objectives
The plant upgrade would position noosa yoghurt to maintain a competitive advantage while solidifying its position
as a major contender in the food and beverage industry. The upgrade would also allow the company to increase its
quality of service through improved network traffic and increased network uptime and availability.
In addition, it was important for noosa yoghurt to establish a solid network infrastructure that uses standards-based
design elements to comply with current industry regulations. Executing these improvements would give noosayoghurt the ability to expand into additional markets.
To address these challenges, noosa yoghurt needed a robust, future-ready solution that could accommodate its
expected growth, decrease downtime, and promote product standardization.

Panduit® Solution
At the recommendation of Malisko Engineering, Inc., a Panduit ONESM Gold Partner, noosa yoghurt consulted withPanduit Advisory Services to design the complete physical layer of its new industrial network. Malisko Engineering
is strongly committed to working with Panduit to help deliver the most efficient solution and superior value to noosayoghurt. The Panduit/Malisko Engineering collaboration prompted noosa yoghurt to deploy a network designthat aligns with the Converged Plantwide Ethernet (CPwE) Cisco Validated Designs (CVDs) to reduce risk, time todeployment, and total cost of ownership. Malisko Engineering was also responsible for the full logical design andconfiguration, including specification and commissioning of the active network and security gear.

Design
The new design was created under CSI Division 27 specifications. It comprises various systems from the Panduit
offering and has allowed noosa yoghurt to simplify its industrial network and IIoT deployment. These systems include
a manufacturing fiber backbone, enterprise fiber backbone, and a spare fiber backbone for future scalability.
Panduit provides expertise in physical infrastructure deployment for CPwE using best practices and a building
block approach. This approach allows noosa yoghurt to achieve a simplified, resilient network and IIoT deployment
designed to enhance industrial network performance.
Malisko Engineering recommended a structured cabling approach using permanent links for copper end points out inthe field, improving operational efficiency, productivity, and flexibility. The design team communicated best practices
aligning with TIA standards and helped noosa yoghurt adopt the use of DIN rail mount patch boxes and single-port
patching inside control panels. To mitigate risk and achieve resiliency in critical process areas, Malisko Engineering3

incorporated both redundant star and REP ring topologies in various areas of the plant. Additionally, the design
called for redundant backbone pathways from one end of the plant to the other. This ensures continuous availability
between the server room and the network core located in the middle of the plant.
The solution for noosa yoghurt’s 32,000 square feet new facility consists of the Pre-Configured Micro Data Center(MDC), Switch Ready Network Zone System, Pre-Configured Industrial Distribution Frame (IDF), control panel
solutions, and fiber and copper connectivity. The CPwE CVDs that Malisko Engineering specified were developed
through strategic partnerships with Cisco (networking and switching technology) and Rockwell Automation.

Connecting the Enterprise to the Plant Floor
The MDC facilitates the connectivity from the plant floor to the enterprise, giving greater visibility into themanufacturing processes to quickly identify problems and maintain network uptime. The MDC is in a small telecom
room that houses the server assets for manufacturing operations. It includes a fault-tolerant server running several
virtual machines for the plant’s automation system in addition to the network and security hardware required to build
a robust Industrial Demilitarized Zone (IDMZ) between the enterprise and manufacturing zones.

Distributing Ethernet Throughout the Plant Floor
Integrated Network Zone and Switch Ready Network Zone Systems are deployed throughout the industrial network.
The Integrated Network Zone Systems use Rockwell Automation Allen-Bradley® Stratix™ Industrial Ethernet switches
along with a battery-free, Ethernet-enabled Uninterruptible Power Supply (UPS) to reduce maintenance and ensure
maximum switch uptime. The Switch Ready Network Zone Systems accept managed switches from various
manufacturers to provide flexibility.
Along with the network zone systems, noosa yoghurt specified NEMA 4X stainless steel sloped-top zone enclosures.
The enclosures were designed and developed for harsh washdown environments such as those found in the foodand beverage industry. Each enclosure features corrosion resistance and mechanical strength, important qualities on
the plant floor. In addition, the enclosures prevent contamination and are easy to clean and maintain, which helps toimprove hygienic conditions. The sloping feature allows for quick washdowns and prevents water from collecting on
the top of the enclosure.
4A later addition to the project was a network zone enclosure housed in noosa yoghurt’s remote waste water
treatment building. This network zone houses a layer-3 Stratix 8300 switch and was configured to act as anautonomous network while still maintaining connectivity to the main network core.
An IDF was selected for quick deployment and protection of noosa yoghurt’s rack-mount Cisco StackWise™ Ethernet
switches. These switches serve as the network core. The IDF also helps achieve rapid and easy maintenance ofnetwork switch equipment. Located centrally on the plant floor, the IDF accommodates a three-switch stack acting
as the distribution/core switches. Centrally locating the network core aided in establishing shorter fiber runs from thenetwork core to the various zones in the process areas. noosa yoghurt used Panduit 8-inch one-to-one patch cords
and various wire managers to connect the Cisco switches, resulting in a well-managed, easy-to-service rack.
Tested and thermally verified by Panduit Laboratories, the IDF achieves 25% faster installation than a nonpre-configured IDF installation. The additional back-end space allows for 3X the cooling capacity over typical
deployments for increased reliability. Provisions for optional AC units, if required, are provided.

Connecting the Machine to Plant Floor Architecturenoosa yoghurt incorporated Panduit IndustrialNet™ patch cords to support Industrial Ethernet from the Local Area
Network (LAN) based support offices to the processing devices on the plant floor. The industrial Ethernet patch cord
is a key component to an overall Industrial Ethernet application. It is the interface that protects the integrity of theEthernet data transfer from the switch or PLC out to the devices or up to the horizontal plant backbone.

Deploying Ethernet on the Machine
The backbone of the industrial network consists of Dielectric Conduited Fiber (DCF) OM4 multimode fiber to meetcurrent environmental requirements and future performance needs. DCF fiber provides high-density connectivity
and ease of installation within buildings and allows easy troubleshooting for noosa yoghurt’s network connections.
The J-Pro™ Cable Support System routes the DCF fiber, maintaining bend radius control, which helps prevent
degradation of cable performance. In addition, the conduited cable is color-coded aqua for easy identification innoosa yoghurt’s existing pathways, which also contains various power cabling and pneumatic tubing.
56Strengthening the Network from the Ground Up
The grounding and bonding system reduces intermittent failures and personal hazards. Visually verifiable connections
and dedicated grounding paths help maintain noosa yoghurt’s system performance and protect personneland equipment.

Business Benefits
noosa yoghurt’s new industrial network system supports the increased production demand while effectively
managing risk to its physical layer. This decreases challenges in its physical infrastructure as it increases network
availability and reliability. Panduit Advisory Services and Malisko Engineering understood the importance of thelogical and physical topologies to meet system requirements and identified future growth needs while suggestingsuitable solutions.
Rexel’s technical assistance and history of working with other partners in the ecosystem helped to ensure theproducts were on site in a timely manner. This positively impacted supply logistics and allowed the installation toremain on schedule. Piper Communication Services, Inc. handled the electrical and office low voltage installation andsubmitted the 25-year Panduit Industrial Automation Certification PlusSM System Warranty. This warranty provides
noosa yoghurt with the assurance that its newly installed cabling system will meet performance expectations andfuture networking needs.

“Panduit Advisory Services provided a single sourcefor our projects to reduce specification, evaluation,and procurement time. Panduit’s relationship withMalisko, Rexel, and Piper Communications ensured
timely responsiveness to deliveries and simplified
sourcing, a demonstration that all parties understood
our business needs. The turnaround time was very
quick and we are very pleased that there has not been
one service call since the installation.”
Trevor Schuetz
Lead Network Administrator, noosa yoghurt* All trademarks, service marks, trade names, and product names appearing in this document are the property of their respective owners.

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