Rockwell Automation, Inc. has enabled Heaven Hill to embed digital transformation into its new production facility in Bardstown, KY, through the deployment of the PlantPAx modern distributed control system (DCS). The solution, implemented by Rockwell Automation partner Opus Integration, was selected to increase efficiency and provide a robust foundation for long-term digital optimization at the site, which launched in 2025. This integration marks a significant modernization for the world's largest independent bourbon maker, bringing operations back to Bardstown for the first time in decades following a fire that destroyed its previous distillery.

Heaven Hill required a system capable of delivering full plant visualization, robust cybersecurity, and support for future AI-driven initiatives. The PlantPAx DCS provides a cohesive view of the entire distillery, transforming how operators engage with the production environment. By utilizing modern interlock objects, the system allows operators to immediately identify issues preventing equipment from running, thereby reducing troubleshooting time and eliminating the need to sift through code or make multiple support calls.

The implementation also focuses on data-driven operational improvements. Operators can now analyze historical trends and compare past production runs directly through the system. This capability supports anomaly detection, process optimization, and continuous improvement within the distillery's operations.

Key Implementation Details

Heaven Hill, known for brands such as Elijah Craig and Evan Williams, has crafted bourbon for over 90 years. The decision to utilize Rockwell Automation's technology ensures that the new facility is fully modernized from its inception, positioning the company for future scalability and efficiency gains.

Rockwell Automation, Inc. (NYSE: ROK) announced the availability of FactoryTalk ResilientEdge, a next-generation execution architecture designed to support autonomous manufacturing operations across highly-automated environments. The platform delivers a unified execution layer spanning machines, people, and production systems, combining low-latency edge execution with cloud capabilities for analytics, AI training, and enterprise orchestration. This architecture ensures continuous operations even during connectivity loss, addressing the need for resilience in modern manufacturing.

Unified Execution Model

FactoryTalk ResilientEdge is built on FactoryTalk Optix and integrated across Rockwell Automation's portfolio, including Plex Manufacturing Execution System (MES). It unifies plant models, connectivity, execution, and intelligence into a single framework, eliminating the divide between Operational Technology (OT) and Information Technology (IT). Key features include a shared production model, native interoperable connectivity, real-time edge execution with embedded business logic, and cloud-scale analytics and AI.

AI-Driven Autonomy

The platform supports advanced analytics, AI, and closed-loop optimization without compromising plant-level performance. With 95% of manufacturers advancing AI and machine learning initiatives, FactoryTalk ResilientEdge enables a new class of manufacturing execution. It allows manufacturers to scale automation, intelligence, and autonomy while preserving cloud advantages, helping deploy faster and lower total cost of ownership.

Scalability and Security

FactoryTalk ResilientEdge is optimized for Rockwell Automation ecosystems while remaining open and interoperable across heterogeneous production environments. Its security, interoperability, and scalability reflect Rockwell's elastic MES solutions. By reducing integration complexity, centralizing monitoring, and supporting modular scalability, the platform lowers lifecycle costs and accelerates deployment, enabling phased modernization strategies.

Key Features

FactoryTalk ResilientEdge is available globally today, representing a foundational shift in scaling execution systems for manufacturers.