Customer application 29 June 2026

Where the Chemistry Works – Henkel Digitizes Surface Treatment With WAGO

Metal pretreatment is evolving: digital, connected, and fully traceable.

Frank Krude, Manager of Application Engineering at Henkel, and his team developed the Lineguard ProcessControl 200 – an intelligent dosing system that captures process data in real time using WAGO components and then visualizes it. Since last year, cloud integration has taken the system to a new level: greater transparency, near end-to-end traceability, and detailed insights into dosing deviations help improve process reliability and reduce resource consumption in a sustainable way. Today, the solution is not only a success within Henkel, but is also in high demand among customers worldwide. With its open and scalable control and I/O platforms, WAGO has long been a trusted partner of the chemical company and is deployed in production systems and control cabinets across all facilities.

This Article Explains:

how Henkel developed the Lineguard ProcessControl 200 as an intelligent dosing system using WAGO components,
the role of new cloud integration in enabling near-complete traceability of batches and setpoint deviations,
the advantages of WAGO’s open controllers for customization and future-proof automation,
and how Henkel integrates the Lineguard ProcessControl 200 as a tailored service solution for external customers.

Innovation through Cooperation

Where the Chemistry Works: Henkel relies on WAGO for intelligent dosing technology.

Full Control Instead of Flying Blind: The Lineguard ProcessControl 200 Receives a Cloud Update

With Lineguard ProcessControl 200, Henkel has redefined metal pretreatment: WAGO components enable continuous data acquisition and worldwide access to all relevant process parameters. Cloud integration significantly increases transparency of consumption, runtimes, and downtime, while enabling near-complete batch traceability. The result: more stable quality, reduced chemical usage, and measurable cost savings. This innovation was recognized with the Fritz Henkel Innovation Award.

“Off the Shelf” Is a Thing of the Past: Tailored Service Solutions for External Customers

Henkel no longer uses the Lineguard ProcessControl 200 solely for internal applications. As part of customer projects, the company analyzes each production environment on-site and customizes the solution to meet specific process requirements. The open programming environment of WAGO controllers enables rapid modifications, edge functionality for on-site analytics, and seamless integration with cloud platforms.

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Components from WAGO

Detailed overview of the WAGO products used in the project

Controllers

Ensuring availability for machines and systems: With high performance, low power consumption, a wide range of interfaces, compact design, and robust safety features, WAGO’s programmable logic controllers (PLCs) provide cost-effective automation solutions for a variety of applications.

Your Benefits:

Programmable with CODESYS in accordance with IEC 61131-3
Scalable computing power
Suitable for use in harsh environments
Ideal in combination with the WAGO I/O System 750

Industrial IoT

WAGO Automation is open for seamless connection to the world of the Industrial IoT (IIoT). Our comprehensively networked infrastructure readily integrates all data into IT systems, enabling end-to-end communication from the field level to the cloud.