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Technical project experience

Automation engineering across production and process industries.

Representative examples of PLC, HMI, drives, control panels, industrial networks and commissioning work. Industries are identified to show relevant experience; every customer, site and commercially sensitive detail remains confidential.

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Industries supported

Engineering shaped around the application.

Food & beveragePackaging machineryMaterial handlingProcess manufacturingOEM equipmentGeneral manufacturing

Anonymised engineering case studies

Technical delivery, clearly explained.

These summaries describe the engineering methods and technologies used without disclosing customer names, plant locations, source code, drawings or protected process information.

Bench-tested PLC, HMI, 24-volt power supply and industrial Ethernet equipment Dual-motor operator interface showing speed commands, status, alarms and trend navigation PLC and HMI software verification using a development workstation and control test bench 01Food & beverage production equipment

PLC · HMI · Ethernet control

Compact PLC and HMI control system for dual-motor machinery

A compact machinery-control package was developed and functionally verified on a dedicated test bench before integration with the production equipment.

Engineering challenge
Develop and prove independent control of two motor channels away from the live machine, while making operating states and faults clear to the user.
Technical delivery
Structured Micro820 PLC software, PanelView HMI development, start/stop and speed-setpoint control, Ethernet communications, ready and fault status, alarm reset, trend navigation, bench wiring and functional simulation.
Engineering outcome
A bench-verified control package with clearer operation and diagnostics, reducing commissioning uncertainty before connection to field equipment.
Allen-Bradley Micro820PanelView HMIIndustrial EthernetMotor controlAlarms & trendsBench testing
Siemens S7-1500 PLC and I/O modules in an industrial control panel 02Food & beverage manufacturing

PLC · HMI · Modernisation

PLC and HMI upgrade for existing production machinery

An existing control system required functional changes, improved operator information and a controlled commissioning approach that reduced disruption to production.

Engineering challenge
Understand the installed sequence and interfaces before modifying live production software.
Technical delivery
Verified software backups, PLC sequence and interlock changes, I/O and permissive review, HMI alarm development, functional testing and controlled software handover.
Engineering outcome
Clearer machine status and diagnostics, updated control functions and a maintainable record of the commissioned software.
Siemens S7TIA PortalHMIPROFINETI/O testing
SEW drive integrated within an industrial control cabinet 03Packaging and converting machinery

Servo · VSD · Motion control

Servo and variable-speed drive integration

Motion hardware was coordinated with the PLC sequence, operator controls, electrical interfaces and machine interlocks to create one maintainable control solution.

Engineering challenge
Integrate speed and position control while maintaining safe states, repeatable operation and useful fault feedback.
Technical delivery
Motor and drive data review, parameter configuration, control-word and status integration, homing and positioning logic, brake control, HMI diagnostics, tuning and commissioning records.
Engineering outcome
Coordinated motion operation with documented parameters, defined interlocks and clearer information for future maintenance.
Servo positioningVariable-speed drivesPLC integrationDrive telegramsCommissioning
Siemens SINAMICS multi-drive control panel during system integration Aligned variable-speed drives and field wiring during control-panel build Detailed view of SINAMICS drive hardware prepared for commissioning 04Material handling and logistics

Conveyors · Networks · Drives

Multi-drive conveyor automation and system integration

A PLC-controlled conveyor application required coordinated motor zones, field sensors, equipment interfaces and operating modes across the handling system.

Engineering challenge
Control material flow reliably while presenting jams, device faults and interlock conditions clearly to operators.
Technical delivery
I/O mapping, automatic and manual sequences, motor permissives, drive speed references, sensor logic, industrial communication, alarm handling and structured commissioning tests.
Engineering outcome
A repeatable conveyor sequence with practical fault isolation, defined recovery behaviour and recorded functional evidence.
Conveyor controlMultiple VSDsIndustrial EthernetField sensorsHMI diagnostics
Siemens S7-1200 PLC and distributed control wiring 05Process manufacturing

Analogue I/O · PID · Process control

Analogue measurement and PID control improvement

A process-control application required clearer engineering-unit scaling, selectable control modes and a structured review of PID behaviour.

Engineering challenge
Confirm signal scaling and control direction before improving stability and operator understanding.
Technical delivery
4–20 mA scaling checks, setpoint and limit handling, manual and automatic mode logic, PID parameter review, alarm behaviour, HMI indication and functional testing.
Engineering outcome
More transparent process-control behaviour with traceable configuration, consistent engineering units and clearer operator interaction.
4–20 mAPID controlAnalogue scalingSetpoint managementHMI alarms
Industrial control panel internal wiring and PLC I/O during construction Stainless-steel control enclosure with HMI and integrated automation hardware during commissioning 06OEM machinery and general manufacturing

EC&I · Control panels · FAT/SAT

Electrical control design and commissioning

Electrical design, automation hardware and test documentation were developed together so the installed control system could be built, verified and maintained consistently.

Engineering challenge
Align hardware, field interfaces, software requirements and acceptance evidence within one controlled design.
Technical delivery
Control architecture, hardware selection, electrical schematics, I/O schedules, panel and terminal details, device interfaces, FAT procedures, SAT support and as-built updates.
Engineering outcome
Coordinated electrical and software information supporting installation, commissioning, acceptance and future maintenance.
AutoCAD ElectricalControl panelsI/O schedulesFATSATAs-built records
Industrial control panel with Allen-Bradley PLC and PowerFlex drives 07Multi-industry production support

Diagnostics · Recovery · Site support

Control-system fault diagnosis and recovery

Remote and on-site support was used to investigate PLC, HMI, drive, network and electrical control faults using an evidence-led diagnostic process.

Engineering challenge
Separate symptoms from root causes and define a safe route back to operation without introducing uncontrolled software changes.
Technical delivery
Backup and version verification, online PLC diagnostics, I/O signal tracing, drive fault and parameter review, network checks, corrective action, recovery tests and documented findings.
Engineering outcome
Traceable fault resolution with clear recovery actions and recommendations for maintenance or follow-on engineering.
PLC diagnosticsDrive faultsIndustrial networksSignal tracingRemote supportSite support
Confidential by design.Industries and engineering methods are shown to demonstrate relevant capability. Customer identities, site locations, production data, source code, drawings and commercially sensitive information are excluded.

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