Control System to Integrate New Process in Harrisburg, PA Challenge: Design and program a new control system for the batch management system. Solution: Our team provided all control panels, VFDs, Ethernet, PLC and HMI programming, startup and commissioning, drawings, and electrical contractor guidance. This project solution also included Rockwell hardware migration. Controls Upgrade for Coolers […]
Beverages
CIP Skid Controls for Beverage Producer in Huntingdon Valley, PA Challenge: The customer had a used CIP skid without any controls or instrumentation. Solution: Our team developed a scope, specified instrumentation, and provided a conventional CIP program with pinning, pegging, cycles and steps. We built a control panel and supplied the drawings and an operational […]
General Foods
Upgrade Controls for Packaging Machine in Secaucus, NJ Challenge: Upgrade electronic controls for rice packaging machine running legacy controls. Solution: Electronic controls for rice packaging machine were upgraded to include a new CompactLogix PAC replacing an obsolete SLC 100. We provided a new consolet enclosure with a Rockwell PanelView HMI screen, and new Electro Cam […]
Meats & Proteins
Rapid AHU Controls Upgrade Beef Packer in Souderton, PA Challenge: Environmental system control upgrade for this beef processor. This unit was no longer supported by the manufacturer. It was desired to have visualization and control from the plant wide Ignition SCADA system. Solution: We added a new CompactLogix PLC, repaired deteriorated controls and added new […]
Chemicals, Rubbers & Plastics
Control System Upgrade for Rubber Coated Textile Manufacturer in Beacon, NY Challenge: Rotocure vulcanization machines dating to the 1940s needed new controls. Existing controls were old, inadequate, unreliable, in disarray, and obsolete. Solution: We engineered a PLC control system that supported all the time, pressure, and heat characteristics needed for vulcanization. We built multiple panels […]
Institutional
Door Control for County Correctional Facility in Central PA Challenge: This facility suffered from an improperly designed and unfinished door control system. Solution: Our team performed an evaluation of the system to locate problems. Based on our evaluation, we found and corrected numerous Wonderware development issues, as well as wiring prolems. We updated their software […]
Industrial Machine/Products Manufacturers
Controls and Instrumentation in a New Facility for Ingredient Supplier in Pennsauken NJ For this project we supplied several multiple door enclosures of controls and value added services driven by a Siemens DCS. Sub-systems included bulk liquid and dry handling, centralized CIP, and production line supervision. For this solution, we used: Siemens ET200 IO 30 […]
Material Handling & Logistics
Controls for Bulk Fertilizer for Intermodal Distribution Terminal in Fairless Hills, PA Challenge: Provide controls for the expansion of a bulk fertilizer warehousing system with a system of conveyors and diverters that transports bulk ship-borne urea to storage domes which can then be distributed to rail or truck. Solution: We created the controls scope, provided […]
Metals & Mining
Controls for Conveyors and Screener Addition at Crushed Stone Quarry in Andreas, PA Challenge: The quarry needed to add multiple conveyors and screeners to its operation. Solution: Our team utilized multiple licenses of AVEVA InTouch in the supervisory control towers. We upgraded the HMI, installed new PLC hardware, and performed termination to new IO, devices, […]
Packaging Industry
Positioners Upgrade for Corrugated Printer in Collegeville, PA Challenge: Automatic positioning for machine setup was done by obsolete positioners. Solution: After a PLC upgrade, we modified 13 axes with conventional PowerFlex 525 VFDs utilizing the motor encoders. All operator setup and control are done through FactoryTalk View SE. Servo Upgrade for Consumer Tube Packager Tube […]