CASE STUDIES/PROJECTS

Geothermal Energy Plant

This was a pilot plant to test certain drilling procedures for geothermal energy. Our customer supplied multiple 1500 horsepower medium voltage pump motor controls for this project. We did the programming using a Rockwell ControlLogix platform to control pumping water up from beneath the earth, turning it to steam and pumping the condensate back down into the earth.

Major Metal Service Centers

Ongoing support for various projects at a major metals service center. Projects involving machine controls, material handling and inspections.

Major Plastic Container Manufacturer with Multiple Facilities

Ongoing support via service calls and projects with a plastic container manufacturer. Mostly machine upgrades to minimize
obsolescence and maximize quality and efficiency. 100% inspection of containers using Keyence machine vision hardware.

Food Ovens

Multiple clients that produce food products. Controls upgrade to multiple gas fired ovens to reduce variability, improve quality and throughput.

Major Food Container Manufacturing

Ongoing service calls and projects for a foam products manufacturer. Systems ranging from bulk handling of both virgin and recycled material. Servo systems to regulate throughput speeds and material thickness.

Waste Water Treatment

The largest project in our history involved a complete control system for a new water treatment facility. Our customer
developed an anaerobic process for wastewater treatment, saving hundreds of horsepower in aeration expenses. We supplied the entire automation control system, PLC cabinets, operator consoles, instruments, valves, and motor control
centers.

Corrugated Board Manufacturing

Ongoing support and projects for multiple corrugated board manufacturers.

Powder and Liquid Paint Manufacturing

Ongoing support and projects for powder and liquid paint manufacturers. The liquid manufacturer produces both water based and solvent based products. Projects involve bulk handing extruders, fillers, conveyors, etc.

Railroad Track Recycling

This major railroad company has a facility that brings in railroad track up to ¼ mile in length. It cuts out any bad spots, cuts it to 80-foot maximum lengths and welds it back together to ¼ mile lengths. Most of our work with them has been to upgrade old PLC systems to newer platforms. Our largest project with them was an upgrade to the controls of their material handling system which moves around the 80-foot lengths of track and welds it back together.

Beverage Manufacturing

Ongoing support and projects for multiple beverage facilities. One of our most successful projects involved a customer who had just purchased a $3 million filling line. The OEM declared it complete when it met the functional specification of 1100 containers per minute. Working with a very smart and dedicated maintenance supervisor, with multiple tweaks over a period of a year, we maxed out the line at 1600 containers per minute. Simple tweaks produced a 50% increase in throughput. Another similar short project with another beverage manufacturer produced a 10% increase in just one day.

Rubber and Tire Manufacturing

Ongoing support and projects for multiple rubber and tire manufacturers . Our most notable project was a batching system which supported a single mixer with approximately 2000 recipes and 2000 different ingredients. A batch queue could be scheduled weeks in advance and modified on the fly.

Major Brand Caulk Manufacturing

Ongoing support and projects. Our most notable projects were three lines and involved visual inspection of cap placement on a caulk tube using Keyence machine vision hardware. This involved detecting the position of a white cap in a white tube with usually a white product. The system has no room for error.