Automated ETCH Lines

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This project consisted of the design and fabrication of a control system for chemical etch & cleaning lines for aerospace parts manufacturing. Our scope of service consisted of the electrical and control engineering, PLC software development and SCADA system development. The system consisted of a main control panel including a PLC based processor with four remote distributed I/O panels for the four lines of 40+ tanks.

The main control panel provided a single operator interface to the Ignition!® SCADA system giving an overview of all systems and detailed control of individual components. The remote monitoring of the system is also made possible through secure VPN client connections. In addition to real-time monitoring the SCADA platform provides detailed historical trend reporting customizable by the operator. Future expansion options include SMS text notifications for system alarms as well as mobile app monitoring and control functions.


Location: Laconia, NH


Effluent Pretreatment System

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This project consisted of the design and fabrication of a control system for batch treatment processing of industrial manufacturing waste. Designed for a pharmaceutical-grade stainless steel tank manufacturer, the system performs automated processes to chemically treat manufacturing waste. Batch treatments can be customized by the operator on the HMI to control that numerous automated pneumatic valves, tank mixers, process pumping, and chemical dosing.

Our scope included electrical and control engineering, fabrication of the system control panel, PLC programming and HMI software development.


Location: Syracuse, NY

Process Water Recycle System

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Our team designed multiple industrial control panels, developed PLC programming and HMI graphics for waste water recycle systems. The system included Reverse Osmosis, Micro-Filtration, and Multi-Layer Filtering processes used to treat process rinse water from various metal finishing production lines. Existing waste treatment systems were also integrated into the multiple operator interface terminals to allow for centralized control and monitoring across the facility.

Interfacing with the facilities corporate IT network was also implemented to allow for management level monitoring and performance data evaluation. SMS and email notifications of process alarms are available to the operators based on their individual shift schedules.

Our team was involved from the conceptual stage of process and instrumentation diagrams to the final commissioning of the system at the customer’s facility.


Date of Construction: 2019

Location: Batavia, New York

Extrusion Machine Upgrades

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With the increased demand for flat panel displays the need for high clarity multi layer display film is a must to maintain market share. We worked with a team of process engineers on the expansion of an existing extruding machine. The upgrades would allow two processes to be completed at one time and decrease the risk of damage to the film from handling. In order to meet the requirements of the new system and maintain minimum installation downtime, a new control panel was designed and fabricated.

The panel was designed to house a new PLC, a modular bus system for heating controls, and variable frequency drives for control of the 100 horse power extruder and associated melt pump. The new control system was integrated into the existing process with a control net network. Two additional operator interface panels were installed for operator control at the machine and also in the control room.

Our scope included providing the process control design, software and graphics development, custom manufactured control panel and engineering support during the transition to the new system.


Location: Rochester, New York


Western New York Flour Mill

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Designed the power distribution and process controls for the wheat receiving and distribution expansion at a flour mill located in Churchville, New York. The power distribution included a new 2000A utility service with connection to motor control panels serving the new receiving/distribution equipment and storage bin aeration fans.

The process controls consisted of a custom designed PC based graphic terminal in the main control room with a main PLC control panel and two motor control panels. Panels and devices were interconnected with an Ethernet based control network with a combination of fiber optic and copper cabling. In addition to the electrical and process control design our scope included providing the software and graphics development, onsite startup services and the custom manufactured control panels.


Location: Churchville, NY