Process Control

Loop Control

Controlling process loops with the correct response and disturbance rejection characteristics can be a non-trivial task. Our engineers will work with your team to identify the best control loop strategy for the equipment you have and make recommendations for the addition of equipment that will result in a finely tuned control loop if needed.

Examples of some of the means we use to tune loops include:

· Adaptive gains for loops requiring different response characteristics at different process circumstances ·
· Multi-Loop selection for single control elements using multiple process feedback instruments ·
· Ratio control for maintaining a quantity relationship between multiple ingredients regardless of flow ·
· Cascaded PID loops for finely tuning disturbance rejection and maintaining a steady process ·
· Split range control for heating/cooling loops for a single vessel or unit simliar to an extruder's heated/cooled barrel zone ·
· Step response benchmarking (automatic/manually induced setpoint changes) ·
· Autotuning when available ·

PLC platforms we have successfully implemented include:

· Allen-Bradley ·
· Omron ·
· Schneider/Modicon ·
· GE ·
· ABB ·
· Siemens ·

Stanalone controllers we have successfully implemented include:

· Honeywell ·


A process can only control as well as its feedback devices measure and its control elements modulate. We have experience with many brands of instrumentation with the following output signals:

· Profibus PA (for hazardous locations) ·
· Foundation Fieldbus ·
· HART ·
· 4-20 mA ·
· and more.... ·

We have experience types of instruments of the following types:

· Thermocouple ·
· RTD ·
· Temperature Transmitters (TT) ·
· Pressure Transmitters (PT) ·
· Flow Transmitters (FT) Magnetic and Mass ·
· pH ·
· Conductivity Transmitters ·
· Turbidity Transmitters ·
· and more.... ·

Control Elements

We have experience with many brands of control elements of the following types:

· Temperature Control Valves (TCV) ·
· Solid state heater controls ·
· Flow Control Valves (FCV) ·
· Positive Displacement Pumps ·
· Centrifugal Pumps ·
· Mix-Proof Valves ·
· Exhaust Fans/Dampers ·
· Induced Draft (ID) and Forced Draft (FD) fans ·
· Burner control motors ·
· and more.... ·


Custom PLC Programming

Our controls team is well-versed in writing structured, robust, maintenance-friendly PLC code. Often, this can be the most cost-effective means to upgrading existing systems. Depending on the applicable industry, ladder logic, structured text, sequential function charts, or function block may be the language of your choice. No matter which language you desire, our professionals will deliver an easy-to-navigate program that will minimize downtime and help you to get your systems producing again.

Examples of some of the systems our engineers can and have developed include:

· Food & beverage batching and bottling systems ·
· Cooling tower systems ·
· Barge unloader systems (clamshell/grab bucket, continuous dig, barge hauls) ·
· Tripper car/deck systems ·
· Industrial boilers (coal-fired and gas) ·
· Extruders and supporting process rolls and winders ·
· Coal yard conveyors ·
· Water treatment systems ·
· Industrial cure ovens and dryers ·

PLC platforms we have successfully implemented include:

· Allen-Bradley ·
· Omron ·
· Schneider/Modicon ·
· GE ·
· ABB ·
· Siemens ·

PLC Program Translation

Do you have a proven PLC program that you trust and the only problem is that it is running on antiquated hardware? Many controls platforms offer utilities that translate old programs and create new versions of the same logic to run on new hardware. These utilities can perform this translation with high accuracy, but some errors remain in the translated programs. A typical RSLogix 5 program that is translated using Rockwell Automation’s translation utility will contain between a couple hundred and a couple thousand errors. Our controls team can correct and update these errors so you can get back to what you do best. We also utilize proven algorithms to correct misspelled words in tag descriptions and rung comments. Call or use the contact form below to discuss other features of our program translation services.

PLC Program Migration

Changing PLC platforms? Let us help you redesign your system and migrate the PLC code. Our controls team has extensive experience migrating PLC systems to new platforms including GE 90-30 to MicroLogix, GE Series-6 to ControlLogix, MicroLogix to CompactLogix, PLC 5 to ControlLogix, Modicon 984 to ControlLogix, Modicon 984 to Quantum, and more.

PLC Program Re-Write

Complimented by our controls team’s custom programming abilities, our controls team has the ability to reverse engineer your existing old or poorly written PLC program and deliver a structured, robust, maintenance-friendly program that functions the same as the original. This option can allow you to virtually walk away from the project while we do the work for you. Depending on the applicable industry, ladder logic, structured text, sequential function charts, or function block may be the language of your choice. No matter which language you request, our professionals will deliver an easy-to-navigate program that will minimize downtime and help you to get your systems producing again.


Whether you are upgrading Allen-Bradley 1336 drives to PowerFlex 753 drives or migrating from an Allen-Bradley 1395 drive and DC motor to a PowerFlex 755 drive and AC motor, we can help you make the transition. We have successfully upgraded and migrated web lines, cranes, fans, and more to newer and different technologies spanning multiple brands of equipment.


The most common drive control method is speed control. Although, simple in concept, some applications require precise speed control or upgrade techniques to produce a quality product. We can help you complete your system with precise, responsive motor speed control for any type of load including those controlled by wound rotor motors. Inquire about our pre-engineered drive systems today.


Controlling web tension throughout a process can be one of the most critical aspects of production. Stretching of the web can damage product and allowing droop can cause winding or process issues. Our controls team is well-versed in tension control using AC drives and DC drives to maintain web integrity by utilizing effective inertia compensation and diameter calculations. We have experience with center-driven, surface-driven, and dual-turret blown-film plastics winding and unwinding as well as metal winding and unwinding, barge hauls, and high-inertia loads. Inquire about our continuous barge unloader controls today.

Load Sharing

Our controls team has multiple success stories illustrating our abilities to control loads with multiple motors including grab bucket (clamshell) hoists utilizing hold and close motors, over-head chain conveyors, and rigidly-coupled torque followers. Antiquated drives can cause costly downtime. Give us a call or use the contact form below to discuss our pre-designed systems.


We have positioning capabilities using servo drives, standard drives with motion controllers, indexers, and more. Whether your system is in need of a one-to-one upgrade or a complete redesign, we can handle any variety of complex positioning schemes including cut-to-length, indexing, gap control, and more.


Regenerative drive solutions can save you money in energy. Whether you need an AC or DC drive system we can help. We have designed and implemented multiple common bus systems, single and multi-motor cranes, and barge haul systems.


Machine HMI

Machine level Human-Machine-Interfaces (HMI) can provide data and control to operators quickly and at a low cost. Our controls team can develop applications that are direct and to the point for your operators or we can develop aesthetically pleasing graphics. Machine level HMIs typically require maintenance to be executed locally at each device.

Distributed Client/Server HMI

Distributed HMI systems are becoming more popular. Although more expensive than Machine HMIs, server-based, distributed HMI systems can centralize your deployment efforts as well as enable easier data collection. Call us or contact us via the form below to discuss our solutions.


Loop Tuning

Process control requires PI and PID loops to be tuned accurately and precisely in order to minimize Out-of-Tolerance (OoT) product. Our controls engineers can help you tune or modifying your existing process loops to include cascades, feed-forward, filtered-feedback, and more.

Extrapolation Correction

Our engineered systems can predict future performance based on previously experienced trends in process variables and modify the control variables to maintain production while notifying you of the trending and possible preventative maintenance required.

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