In Loudon, Tennessee, the American arm of Italian porcelain tile manufacturer Del Conca has transformed its 30-acre facility into a model of industrial automation, powered by a private cellular network from Celona. The decision to replace an unreliable Wi-Fi setup with a 4G LTE system operating in the CBRS spectrum has brought measurable improvements in efficiency, reliability and operational control.
Del Conca’s manufacturing processes rely on a seamless interplay between automated guided vehicles and manned forklifts, both of which require constant, uninterrupted wireless connectivity. Under the previous Wi-Fi deployment, the company struggled with frequent connection drops, interference from metal structures and roaming issues, especially in the transition between indoor and outdoor environments. These disruptions caused production stalls, long truck loading times and challenges with real-time tracking of goods.
Attempts to fix these issues with advanced Wi-Fi techniques, including the use of leaky coaxial cables and strategically placed access points, proved ineffective. Maintenance was costly and network downtime remained a persistent problem. Recognising the limitations of Wi-Fi in such a demanding environment, Del Conca made the shift to private cellular, selecting Celona for its integrated and IT-friendly approach.
Celona’s deployment included eight indoor and four outdoor access points, connected to an on-site Edge appliance and managed via the cloud-based Celona Orchestrator. The entire system was tailored to Del Conca’s existing IT infrastructure, with all traffic securely routed and prioritised using VLAN and QoS policies. In comparison to Wi-Fi, Celona’s solution required fewer radios yet doubled the effective coverage, thanks to the more robust and adaptive signal characteristics of LTE in the CBRS band.
To ensure compatibility with existing operational equipment, Del Conca retrofitted its AGVs with cellular gateways that connect directly to onboard PLCs. Forklifts, meanwhile, were modified to support CBRS by replacing Wi-Fi modules with SIM-enabled cellular modules, enabling rugged tablets to remain connected throughout the facility. This connectivity is essential, not only for work order delivery and verification, but also for location tracking, operational monitoring and remote expert assistance.
The shift has delivered tangible benefits. Automation runs without interruption. AGVs move autonomously through the production line. Forklifts operate with precise guidance. Material handling is faster and more efficient. Errors have decreased. Delays have been cut. Importantly, the new system also offers enhanced safety, as network stability is essential for both robotic systems and human operators to function in tandem.
Beyond internal use, the private network also supports a neutral host architecture. This allows employees to use personal or corporate devices from T-Mobile and AT&T within the facility, bridging a key gap in cellular coverage without relying on traditional public infrastructure. Although Verizon support is pending, the multi-operator support already provides added value to workforce connectivity.
Celona’s deployment at Del Conca is more than a local success. It serves as a replicable blueprint for future expansions, both within the company’s operations in Italy and potentially across other industrial verticals. With the ability to roll out either 4G or 5G using country-specific shared spectrum, Celona’s architecture positions itself as a flexible and scalable solution for global manufacturing environments.
The partnership between Del Conca and Celona underscores the growing relevance of private wireless networks in modern industry. With public RAN and enterprise WLAN markets evolving, private cellular continues to carve out a vital role in environments where mobility, reliability and automation intersect. Del Conca’s experience demonstrates that with the right strategy and technology partner, private wireless can deliver not just technical improvement but a solid return on investment.
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