Rubberlite

Rubberlite Modernizes Operations and Eliminates Downtime

Rubberlite worked with InSource to deliver an innovative fault tolerant supervisory control system using a Stratus & Wonderware architecture that achieved 64% scrap reduction while sales grew 15%.

Title

Rubberlite, a West Virginia-based materials manufacturer, produces custom-engineered polyurethane foams for more than 1,600 customers worldwide across aviation, medical, apparel, and furniture markets. To support their growth strategy and deliver consistent quality, the company needed to modernize aging systems, improve data reliability, and eliminate manual, paper-based processes that slowed productivity.

Building a Foundation for Digital Transformation

To address these challenges, Rubberlite launched a Supervisory Control Systems initiative and partnered with InSource Solutions to design a modern, reliable infrastructure. Together, they deployed Stratus Edge Computing to simplify IT, standardize data collection, and ensure continuous availability of critical applications.

Using Stratus ftServer and AVEVA System Platform, implemented and configured with InSource expertise, Rubberlite consolidated legacy systems, automated key processes, and gained seamless visibility into production operations. The result was a scalable, fault-tolerant environment built for long-term growth.

Transformational Results

By improving data integrity, eliminating manual work, and standardizing processes, Rubberlite achieved measurable performance gains:

• 80% reduction in off-grade material
• 25% increase in sales and production capacity
• Zero unplanned downtime since 2016

Engineers now access complete, reliable data instantly, and operators work from standardized digital workflows, improving quality, consistency, and overall operating discipline.