From concept to completion, Industrial Automation Systems delivers custom PLC programming, electrical design, and systems integration for Food & Beverage, Pet Food, Paste Supply, and Box Manufacturing industries. On time. Every time.
Front-end consulting clarifies scope, direction, and risk that typically includes
IAS delivers comprehensive electrical design services for control systems that support safe, reliable, and efficient operations.
PLCs play a critical role in controlling industrial processes, managing equipment behavior, and ensuring systems operate safely and reliably.
HMIs play a critical role in helping operators understand the health of their systems, view alarms, and take action to keep production moving safely and efficiently.
IAS provides systems integration services that connect individual machines, vendor equipment, and customer-provided systems into a single, uninterrupted production operation.
Challenge
A paste manufacturer experienced downtime, equipment failure, and nuisance alarms on a high-speed filler paste supply feed system.
Implementation
To determine the root cause of the system failures and nuisance alarms, IAS conducted a study on behalf of the manufacturer. An IAS team member visited the manufacturing site to gather more information from plant personnel, observing the problems firsthand. Through this study, IAS determined that the existing control strategy was limited, resulting in a system that cycled on and off regularly. This short cycling caused excessive mechanical stress on the pumps and valves. The customer provided the PLC and FactoryTalk ME application to IAS, and IAS studied and documented the nuisance alarms.
Utilizing information provided by the downstream equipment, a new control strategy was implemented using a PID controller. The nuisance alarms were remedied by modifying the existing PLC program and FactoryTalk ME application. No new mechanical equipment was required.
Result
The new control strategy improved the reliability of the paste supply system. The system no longer short cycled, resulting in less wear on the mechanical equipment. The overall system operated smoothly, no longer requiring the operators to respond to nuisance alarms.
Challenge
A food and beverage manufacturer needed to replace an aging case packer on a packing line that was controlled by an obsolete Allen-Bradley PLC-5 system. In addition to the case packer replacement, the project required new upstream and downstream conveyors.
Implementation
IAS supported the manufacturer in evaluating electrical and controls specifications for multiple case packer options to determine the best fit for the application.
To modernize the surrounding infrastructure, IAS designed a new I/O and VFD panel to meet the requirements of the new conveyors. Following installation, IAS configured the new conveyors and integrated the case packer with the rest of the equipment on the packing line.
IAS also updated Wonderware HMI screens to reflect the new conveyor layout and case packer, providing operators with clear visibility into system performance.
Result
The upgraded system controls improved overall line efficiency by enabling smooth integration between the case packer and conveyors. The new controls architecture eliminated reliance on obsolete hardware, improving system reliability and maintainability. Enhanced HMI visibility also allowed operators to better monitor and manage production, supporting more consistent and efficient operations.
Challenge
A food and beverage manufacturer needed to replace an aging case packer on a packing line that was controlled by an obsolete Allen-Bradley PLC-5 system. In addition to the case packer replacement, the project required new upstream and downstream conveyors.
Implementation
IAS supported the manufacturer in evaluating electrical and controls specifications for multiple case packer options to determine the best fit for the application.
To modernize the surrounding infrastructure, IAS designed a new I/O and VFD panel to meet the requirements of the new conveyors. Following installation, IAS configured the new conveyors and integrated the case packer with the rest of the equipment on the packing line.
IAS also updated Wonderware HMI screens to reflect the new conveyor layout and case packer, providing operators with clear visibility into system performance.
Result
The upgraded system controls improved overall line efficiency by enabling smooth integration between the case packer and conveyors. The new controls architecture eliminated reliance on obsolete hardware, improving system reliability and maintainability. Enhanced HMI visibility also allowed operators to better monitor and manage production, supporting more consistent and efficient operations.
