Global System Integrator Report 2022 December

input #1 at www.controleng.com/information

O NLINE C ONTENTS

 Achieving on-stream control room relocations

—Ted Hoffman and Charles Mills, aeSolutions

 Five control system design challenges for developing wave energy converter

—Chris Hudson, Applied Control Engineering, Inc.

 Simplifying sortation system for recycling company

—Nathan Ferrin, Cornerstone Automation

 Coating line upgrade for packaging and shipping company

—Electronic Drives and Controls

 Developing a successful PLC, I/O system integration plan

—Caroline Zimmer and Mark Podbielski, General Control Systems

 Leveraging real-time data across the enterprise

—Rajah James, Grantek

Global System Integrator

 Upgrading ventilation equipment systems in automotive tunnels

—Nick Hein and Sean Creager, Huffman Engineering

 How data is making a flour mill run smarter and leaner

—Bryan Monroe, Interstates

 Systems integrators support end user self-service

—Ketut Putra, Koidra

 Increasing production with less capital

—Richard Phillips, Polytron

 Robotic welding system enables more welding applications for collaborative robots

—Josh Pawley, Vectis Automation

 Enhancing chemical company control system reliability, performance

—Brad Bonnette, Wood

System integrators: Automation glue

THE GLOBAL SYSTEM INTEGRATOR REPORT

for 2023 is full of reasons to consider an expert system integrator to design, optimize, test, connect, implement and upgrade automated devices and systems to save energy, improve throughput, add quality and augment safety to improve lives and make the world a better place.

Class of 2023: System Integrator of the Year

System Integrator of the Year for 2023 selects three leading control system integrators in three categories based on system integration revenue.

Applications include feeding school children, delivering clean water, manufacturing recycled building materials, and feeding pets. Success starts with a well-planned scope of work, adherence to budget and schedules.

For COVID-19 vaccine manufacturing, a

system integrator “developed a precision control system with programmable logic controller (PLC), human machine interface (HMI) and supervisory control and data acquisition (SCADA), and panel design and fabrication.”

To reach “senior engineering ranks, engineers must demonstrate effective mentoring." This is includes successful project execution integrating less experienced engineers.

Read more starting on page 11.

Outstanding SI projects

This year’s article solicitation asked for the project that “solved a previously unsolvable set of challenges, was completed on time despite a seemingly impossible schedule, integrated sets of technologies or systems in elegant and sustainable ways, involved extraordinary team member collaboration or growth," or some combo. More than 20 feature articles resulted. In the digital edition, click the the headline of each for more online.

Research: SI Giants 2023

Control Engineering and Plant Engineering (CFE Media and Technology) research on System Integrator Giants for 2023 said this about the best system integrator customers: Customers that appropriately evaluate and then trust system integration partners. Successful integration of a new control system to already existing ones. Prefer to work with experienced, committed, and engaged systems integrators, rather than making decisions based on a lower price.

SI Giants said customers expect: Outcome-driven skills to enable the success of the client's project, starting with: “What problem are you trying to solve?” Train engineers regularly and update them with the latest technologies and project management practices. GSIR

Mark T. Hoske is content manager, Control Engineering, mhoske@cfemedia.com, also on behalf of Plant Engineering

Mark T. Hoske

Jose Rivera, Control System Integrators Association

(CSIA)

SIs to increase US manufacturing competitiveness

Manufacturing has changed due to recent global events with an emphasis on being smarter and leveraging all around us. System integrators (SIs) can help manufacturers with digital transformation, smart manufacturing efforts.

As the U.S. rebuilds its manufacturing sector post-pandemic, it creates bona fide business opportunities for the automation industry, including system integrators (SIs). Deployment, in particular mass adoption, is tied to its own set of challenges. SIs can play a key role. I am reminded of the reconstruction of the Japanese industry post-World War II. Japan proved to be very receptive to the quality-related teachings of W. Edwards Deming, an American engineer and others. Many view this openness to manufacturing quality as having significantly contributed to Japan's reputation for innovative, high-quality products, and for its economic power, providing decades of benefits.

Smart Manufacturing has the potential to transform the manufacturing sector and address new challenges, such as resiliency considering supply chain disruptions and labor shortages; sustainability; “local” production and extreme customization (batch size of one) to name a few.

Smart Manufacturing, automation

Automation and system integrators can help integrate related automation and systems for manufacturers. Terminology differsand differences among Smart Manufacturing, digital transformation, Industry 4.0, Industrial Internet of Things (IIoT), but in this case, I will consider the terms to be synonyms. I am guided by the following definition from ARC Advisory Group: “Digital transformation is the transformation of industrial products, operations, value chains, and aftermarket services that are enabled through the augmentation of people and knowledge, through the expanded use of sensors, data and analytics.”

For manufacturing to succeed, it needs to be competitive. Competitiveness revolves around various elements, such as cost position, differentiated and relevant offerings (customizable), access and speed to market, flexibility (with ability to adapt to changing conditions) and, ultimately, resiliency. It

is not limited to individual companies. Successful companies rely on a broad ecosystem of suppliers (including automation and controls) that also need to be competitive and willing to work collaboratively with customers and suppliers.

Events like the COVID-19 pandemic and Russian-Ukrainian war exemplify dramatic changes over short periods of time and the need for rapid responses to new situations. Smart Manufacturing uses automation to help extend the perimeter beyond the factory floor to include supply chains and aftermarket services. In fact, I would posit this holistic approach positions manufacturers for increased competitiveness.

Automation improvements

CESMII is the Smart Manufacturing Institute, a US government funded, non-profit organization to drive Smart Manufacturing. In the May “2022 Smart Manufacturing Market Survey,” by CESMII/Society of Manufacturing Engineers (SME), the majority of respondents (77%) recognized the potential of Smart Manufacturing and identified three obstacles to deploying Smart Manufacturing, where automation and system integration can help:

1. Need for skilled talent.

2. Cost and complexity to implement and integrate.

3. Lack of connection between technology and business strategy.

The US has an opportunity to rebuild its manufacturing sector with automation, controls, system integration. Let’s make Smart Manufacturing happen! GSIR

Jose M. Rivera is CEO of the Control System Integrators Association (CSIA). CSIA is a Control Engineering and Plant Engineering content partner. Edited by Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.

Jose M. Rivera, CEO of the Control System Integrators Association (CSIA) since March 2015, works to help independent system integrators build better companies through the adoption of the association’s best practices guidelines. Courtesy: CSIA

KEYWORDS: Smart Manufacturing, system integration, CSIA

LEARNING OBJECTIVES

CSIA and CESMII help system integrators with Smart Manufacturing. Integrating automation and control devices and systems improves Smart Manufacturing and can improve connections with higher-level systems helping supply chain integration. ONLINE

Click headline in digital edition to see more online on the SI’s role in democratizing Smart Manufacturing, how system integration helps. https://www.controlsys.org https://www.cesmii.org CONSIDER THIS

Are automation and controls helping to integrate your devices and systems for Smart Manufacturing?

Skkynet’s unique DataHub technology is redefining industrial IoT. New security enhancements, unmatched tunneller capabilities to bridge on-premise and cloud, unparalleled flexibility with MQTT enhancements, and connection to historians now available in DataHub10. And, you can future proof your system with alarms and event notifications.

Robert Huschka, Association for Advancing Automation (A3)

Training and certifications help system integrators succeed

Workforce development, automation

A system integrator takes advantage of training and certification programs demonstrate credibility while accessing learning and boosting online visibility for increased customer acquisition.

With the increasing number of robotics and automation system integrators in business today, standing out is critical to success. Being up-to-date on the latest technologies and best practices, and having the certification to back it up, distinguishes integrators for a high level of skill and experience and for having met the exacting requirements a certification process requires.

Training and relevant certifications

Individual robot and automation vendors typically offer training on their specific products, but industry associations can offer more extensive training that will cover multiple technologies. Conferences such as Automate, the International Robotic Safety Conference, the AI and Smart Automation Conference, and the AMR & Logistics Conference offer these kinds of opportunities. In conjunction with Automate, for example, the Association for Advancing Automation (A3) offers integrators education classes to complement certifications programs such as:

Certified Robot Integrator (CRI) Program

The CRI program, established in 2012, helps engineers, managers and executives assess the capabilities of accredited integrators. It offers insights to help companies pre-determine the best integrator for them based on a wide range of parameters such as skills, knowledge, experience, commitment and even financial solvency. If the integrator has been certified, companies have the peace of mind of knowing that integrators who have successfully completed the program possess the capabilities at a very high level to deliver robotic products, systems and services that are safe, reliable and of good quality. This qualification means they have completed a rigorous organization/infrastructure compliance program, examining a number of criteria.

For example, a full site audit will examine capacity, processes, team, leadership and financial solvency. This could answer many of the questions outlined in

this guide. The integrator also will have undertaken safety risk assessments and hands-on testing of key personnel. The CRI qualification verifies much of what companies need to know to help identify which integrators meet their pre-qualification criteria.

Certified Vision System Integrator (CVSI) Program

Vision system integrators certified through the CVSI program are acknowledged throughout the industry as an elite group of accomplished, highly skilled and trusted professionals. A3 also offers a Certified Vision Professional (CVP) for individuals working in the vision and imaging industry who wish to enhance their knowledge and professional status.

Certified Motion Control Professional (CMCP)

A3 offers the fundamental knowledge that benefits everyone working with motion control, motors and automation technologies. The program is designed to ensure professionals have the knowledge they need to advance their careers and benefit their businesses. CMCP’s are an elite group of system integrators, machine builders, manufacturers, end-users and others recognized in the industry for their professional knowledge and expertise.

A3 also offers training in on global robot standards and collaborative robot applications. Not only should you be doing any training possible, but a system integrator client should also expect training. Offer comprehensive onsite training for end-users, including servicing, maintenance, sourcing supplies and parts, and contingency plans should something go wrong. System integrators who focus on training and certifications by third-party entities such as A3 are recognized as accomplished, trustworthy professionals. They leverage certification to enhance competitiveness, winning major integration contracts the untrained and uncertified miss out on. GSIR

Robert Huschka, VP, of education strategies, Association for Advancing Automation (A3). A3 is a CFE Media and Technology content partner.

Workforce Development Insights

uSystem integrators looking to stay up to date should focus on training and certifications to enhance their knowledge base and credibility.

uIndividual robot and automation vendors can offer training on their specific products, but industry associations can go deeper with an emphasis on multiple technologies.

KEYWORDS: system integration, automation, certifications

LEARNING OBJECTIVES

Training and certification programs help system integrators gain credibility, learning.

The Association for Advancing Automation (A3) educates system integrators in robotics, machine vision, motion control.

ONLINE

Click headline in digital edition to see more online. Get more help at https://www.automate.org/ https://www.controleng. com/system-integration/ workforce-development/ CONSIDER THIS How have certifications and standards helped you?

System Integrator of the Year

Eosys, Smyrna, Tenn. - Above $30 million

George T. Hall, Anaheim, Calif. - Under $5 million

NorthWind Technical Services, Sabetha, Kansas - $5 million to 30 million

Details about the class of 2023 System Integrator of the Year winners follow. Prior winners also are named in the Control Engineering and Plant Engineering System Integrator of the Year Hall of Fame at www.controleng.com/SIY. Many great cowntrol system integrators exist, and many are expanding system integration capabilities and talent to help clients remain competitive, relevant and useful in an accelerating world of technology developments and market demands. Congratulations to the applicants who took the time to answer questions and assembled supporting documents to meet requirements to become finalists. Thank you.

System Integrator of the Year 2023, judges, process

Meet the 2023 System Integrator of the Year judges, who volunteer time for the challenging and rewarding selection process. They are asked rank the finalists in each of three categories, divided by system integration revenue. Judges consider the assembled descriptions, metrics and examples of business skills (a thriving business enables engineering creativity), technical competence and customer satisfaction.

Dennis Brandl, chief consultant, BR&L Consulting, www.brlconsulting.com

Adrian Lloyd, CEO and research director, Interact Analysis, www.interactanalysis.com

Larry O’Brien, vice president of research, ARC Advisory Group, www.arcweb.com

Don Roberts, principal, Exotek LLC, www.exotek.com

Shari Worthington, PhD, president, Telesian Technology Inc., www.telesian.com

Mark T. Hoske, content manager, Control Engineering, www.controleng.com

Kevin Parker, content manager, Plant Engineering, www.plantengineering.com

Steve Rourke, co-founder, CFE Media and Technology, www.cfemedia.com

Anticipating future system integration excellence

While winners are announced in the Global System Integrator Report, a supplement to the November/ December 2022 issues of Control Engineering and Plant Engineering, the award traditionally is dated for the following year, in recognition of anticipated excellent system integration work to come. Now, please, learn more about the 2023 System Integrator of the Year companies in three categories.

Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.

Chris Vavra, web content manager, CFE Media and Technology, collaborated on questions. Amanda McLeman, director of research and awards programs, administers the System Integrator of the Year program. www.controleng.com/SIY

Eosys Smyrna, Tenn.

LARGE SYSTEM INTEGRATOR CATEGORY

$30 million and above system integration annual revenue

Digital transformation at Gibson, control system integration for chemical, food and beverage

2023 System integrator of the Year, Eosys, excelled in digital transformation, batch control, and other control and automation system project integration, with emphasis on mentoring and continuing education.

David Lax, Eosys

As a market leader in automation and information solutions for more than 30 years, Eosys has staked our reputation on a commitment to each customer’s success, taking their processes and integrating automation and controls that fit.

Answers

More u www.controleng.com

KEYWORDS: System Integrator of the Year, Eosys, project management

LEARNING OBJECTIVES

System Integrator of the Year for 2023, Eosys, discusses automation projects.

Mentoring and cooperative engineering programs help advance Eosys goals.

Eosys helps drive excellence with continuing education and company ownership.

CONSIDER THIS

How are you encouraging development of younger engineers?

ONLINE

Click headline in digital edition to see more online.

https://www.eosysgroup.com www.controleng.com/SIY

Learn more about Eosys in the Control Engineering and Plant Engineering Global System Integrator Database.

Gibson needed a digital transformation to keep up with COVID-19 guitar demand. Chemical manufacturing needed a distributed control system (DCS) integration. Food and beverage customer needed automation upgrades. These are among successes achieved at Eosys (formerly Premier System Integrators*), leading to its selection at 2023 System Integrator of the Year in the over $30 million in system integration revenue category.

David Lax, president of Eosys, answered questions from Control Engineering and Plant Engineering (CFE Media and Technology) about these and other topics.

Question: Congratulations on receiving the 2023 System Integrator of the Year award: Talk about what this recognition means for Eosys.

It’s an honor to be selected as a 2023 System Integrator of the Year. This recognition is an important validation that we are building a best-in-class company. At Eosys, our desire is to be the preferred integrator of choice for talented employees and customers looking for long-term partnerships, and this honor reinforces that vision.

Question: What has made recent projects a success for your company, in your opinion?

During the pandemic, Gibson Brands Inc., the world’s most iconic guitar brand, saw a massive increase in consumer demand for guitars. Existing systems and paper processes were insufficient, and Gibson needed a digital transformation partner to guide them through this process as efficiently as possible. We began with a solution design and implementation roadmap. In less than six months, the first phase of the digital transformation was implemented at the pilot site. The pilot was a success, enabling Gibson to meet increased production goals while improving traceability and visibility of manufacturing operations. Over the several months, the team enhanced and rolled out digital transformation to two other facilities. As Gibson continues to address market demand, collaboration and planning for future phases of digital transformation are underway.

Eosys completed a $1.2 million automation project for a large chemical manufacturer in the Southeast. We implemented a Foxboro distributed control system (DCS) platform with intrinsically safe controls that included the integration of a redundant Wonderware InBatch batch manager. Eosys successfully executed the project, adapting the design in progress to address supply chain challenges.

We simultaneously completed two multi-million-dollar projects for a well-established consumer brand food and beverage company. The Eosys team’s ability to coordinate and collaborate with engineers across multiple offices was critical to system integration project success.

Question: Are long-term client relationships important?

2023 System Integrator of the Year

“Co-op program engineers get HMI and PLC training and assist with building industrial control panels, control system design and in field operations.“

In a typical year, more than 80% of Eosys business is derived from customers with whom we have multi-year relationships. Long-term partnerships are mutually beneficial, creating greater efficiencies because we understand customers’ business needs and future direction and reducing project lead times and deployment. The deep knowledge gained over time allows us to provide value beyond the services explicitly outlined in the proposal as we evolve to engage the customer with the same-team mindset.

Question: What do you do to help guide younger engineers along in projects?

We instill a culture that everyone has a mentor. We discourage accepting one-person projects that do not allow for a less-experienced engineer to be mentored by a more senior engineer. Our more experienced engineers are expected to treat every project task as an opportunity to build the next generation of Eosys engineers. To reach the Eosys senior engineering ranks, engineers must demonstrate effective mentoring. This is demonstrated through successful project execution that’s measured partly by full utilization of less experienced engineers. More senior engineers also produce onehour technical lunch and learns. For each project assigned, less experienced engineers have formal, written learning or continuous improvement goals, and mentors have complementary mentoring goals. Eosys monitors goal achievement regularly through performance evaluations. This evaluation process is designed to encourage engineers to seek a wide breadth of experience early in their careers and then pursue depth as they progress towards mid-career levels. Eosys encourages engineers to complete industry certifications in technologies aligned with core company competencies.

Co-op program engineers undergo human-machine interface (HMI) and programmable logic controller (PLC) training, assist with building industrial

control panels, participate in the design of an industrial control system and assist in field operations and system integration. GSIR

David Lax is the president of Eosys. Also contributing to this article from Eosys were: Shaun Guy, vice president of business development; Tyler Graham, director of business development - digital transformation; Steve Orth, director of project management; and Tony Valasek, director of engineering.

EMPLOYEE-OWNED EOSYS, previously known as Premier System Integrators, works hard to recruit and develop talent. From left to right, are Shaun Guy, vice president of business development; Andy Ask, vice president of operations; and David Lax, president. Courtesy: Eosys

4 system integration metrics that matter

Each System Integrator of the Year firm for 2023 was asked to quantify progress over the past year using a few metrics. According to Eosys:

1. The corporate team has grown nearly 20%. This investment addresses our future needs to recruit and develop talent, to secure our IT systems, and to expand our business development influence.

2. The team of engineers in cooperative education programs (Co-op) and entry level engineers has grown more than 33%. Our ability to develop highly capable and dedicated employees has been a hallmark of our success over the last 30 years. Over 25% of our 200-plus employees began as a Co-op or entry level engineer with EOSYS.

3. The digital transformation business grew over 20% in our most recently completed fiscal year. Providing digital transformation services broadens our ability to meet our customers growing needs and distinguishes us from our competition.

4. The number of completed continuous improvement (CI) projects has increased nearly 40%. Eosys has a long history of investing in and building a culture of continuous improvement, with a five-person team dedicated to building and evolving internal processes and systems, meeting the needs of stakeholders throughout the organization.

George T. Hall

Anaheim, Calif.

SMALL SYSTEM INTEGRATOR CATEGORY

Under $5 million in system integration annual revenue

SCADA upgrade without downtime: Golden project results

2023 System integrator of the Year, George T. Hall, excelled in SCADA, PLC, HMI, panel design and system

integration in developing and integrating process controls for a COVID-19 vaccine manufacturer and in a SCADA system for a Nevada gold mine.

Michael Howard, George T. Hall GTH

Answers More u www.controleng.com

KEYWORDS: System Integrator of the Year, SCADA, process controls

LEARNING OBJECTIVES

System Integrator of the Year for 2023, George T. Hall, discusses gold mine SCADA modernization and COVID-19 vaccination process controls. Engineering mentoring helps.

Customer satisfaction is strong.

CONSIDER THIS

How are you improving your applications?

ONLINE

Click the headline for more. https://www.georgethall.com www.controleng.com/SIY

Learn more in the Global System Integrator Database.

Upgrade of a supervisory control and data acquisition (SCADA) system at a Nevada gold mine produced golden results as the system integration team at George T. Hall (GTH) tested the new system offline, ran it in parallel, then switched over without unplanned downtime. In addition, a COVID-19 vaccine manufacturer sought to quickly develop the process controls for automating its production system.

MIKE HOWARD, George T. Hall vice president of system integration, stands in front of GTH panels built in its Nevada UL certified panel shop. He is head of Nevada operations and mentors GTH business development engineers, project managers, technical team/engineers, and production team. Images courtesy: George T. Hall

Along with pressure to meet expedited deadlines (as with most pharmaceutical operations), the sequencing and dosing accuracy of the required ingredients for the vaccine recipe was critical. GTH developed a precision control system with programmable logic controller (PLC), human machine interface (HMI), and SCADA, along with panel design and fabrication. These are among successes achieved at GTH leading to its selection at 2023 System Integrator of the Year in the under $5 million in system integration revenue category. Michael Howard, vice president of system integration, George T. Hall, answered questions from Control Engineering and Plant Engineering (CFE Media and Technology) about these and other topics.

Question: What does the award mean?

We are proud to accept the award as System Integrator of the Year for 2023. This recognition is evidence of collective efforts across the organization to excel as system integrators. GTH was founded on core values that continue to drive us forward. For 90 years, we have taken pride in our culture and our people, and consistently strive to provide the best possible solutions to valued customers. We have been extremely focused in the last 5 years on continuous improvements, with investments in new software and training programs for technical teams. We have held CSIA certified status since 2017 and are currently working towards ISO 9001 certification. These initiatives have strengthened our company’s established mission to develop successful partnerships throughout the lifecycle of projects and develop a culture that benefits employees and customers.

Question: Describe some recent projects.

GTH has successfully completed some exciting projects over the last couple of years. Development of younger engineers through mentoring from senior

GEORGE T. HALL takes pride in the people part of its business. Pictured here are some GTH key leadership team members at the Anaheim office, from right: Laurel Kellam, Jr. project manager; Dina Johnson, vice president of operations; Eddie Martinez, lead control systems engineer; Alea Katan, customer marketing manager; Mike Smith, senior operations manager; and Jesse Valenzuela, senior production manager. To every project we bring a kind, generous, creative team that truly enjoys partnering with clients and solving automation challenges.

engineers has been inspiring. These mentoring partnerships have proved to produce innovative solutions throughout the lifecycle of each project, and we’re proud of the work accomplished, specifically with two recently completed projects that required unique timelines and strategic execution.

We were approached by those involved with a Nevada gold mine about SCADA modernization. The system had reached end of life in an application that could not afford to risk unplanned down time. The existing software application was not available to analyze offline, so GTH developed a plan to view the application via secure remote access from our facility 250 miles away, where we developed the new application in human-machine interface (HMI) visualization software from a different software supplier. Challenges along the way included bridging a Modbus Plus network over to an Ethernet network topology. Systems were run in parallel for a short period until the new software was proven, and the old system was unplugged from the network. The client and GTH teams deemed the project a success, especially in bridging old technologies with the new.

During the height of the COVID-19 pandemic GTH was invited to join “Operation Warp Speed” (OWS), a US federally-funded program for vaccine development, manufacturing, and distribution through a public-private partnership. As part of OWS, we partnered with a vaccine manufacturer to quickly develop the process controls for automating the vaccine production system. Along with immense pressure to meet expedited deadlines (common with most pharmaceutical operations), the sequencing and dosing accuracy of the required ingredients for this vaccine recipe was critical. GTH developed a precision control system with PLC, HMI, and SCADA development in addition to panel design and fabrication as part of the scope. The automation offered a repeatable production

process while ensuring safety, quality and rapid production. The project, deemed a success by meeting the deadline to get the system operational, helped company and project team members feel part of the U.S. COVID-19 fight.

Question: How do to help guide younger engineers?

We try to partner younger engineers with senior personnel on projects to learn the industry, our processes and tools. Education may include ISA training, manufacturer web-based or in person training for software applications. A learning management system helps organize and develop training opportunities for all GTH positions. Specific training milestones can further develop our team. GSIR

Michael Howard is vice president of system integration, George T. Hall.

3 system integration metrics that matter

Each System Integrator of the Year firm for 2023 was asked to quantify progress over the past year using a few metrics. According to George T. Hall:

1. Engineering and production utilization 2021: 64% vs. 2022: 69%. “With a renewed focus on our engineering and production team and the tools needed for them to be successful, we’ve identified a noticeable increase in our team’s utilization.”

2. Innovation allocation 2021: 4% vs. 2022: 6%. “With an ever-increasing project work load, we recognize the importance to make time for our team to work on new ideas, which in turn has increased time spent on research and development (R&D) in the past year.”

3. Customer satisfaction: 100 Net Promoter Score: “In 2022 all surveyed customers from completed projects would recommend GTH should they have the opportunity to do so.”

NorthWind Technical Services

Sabetha, Kansas

MEDIUM SYSTEM INTEGRATOR CATEGORY

$5-30 million in system integration annual revenue

System integration impacts: Feeding children, clean water, recycling

2023 System Integrator of the Year, NorthWind Technical Services, automation and control system integration projects help with feeding school children, delivering clean water, and manufacturing recycled building materials, among others.

Michael Bosworth, NorthWind Technical Services

More u

Answers

www.controleng.com

KEYWORDS: System

Integrator of the Year, NorthWind Technical Services

LEARNING OBJECTIVES

System Integrator of the Year for 2023, NorthWind Technical Services, discusses control system integrator project that make the world a better place.

Learn how to improve cost, quality, and schedules for control system integration projects.

Understand what training that engineering college graduates need.

CONSIDER THIS

Are your HMI tags integrated with other software systems?

ONLINE

Click headline in digital edition to see more online www.northwindts.com www.controleng.com/SIY

Control and automation systems NorthWind Technical Services builds and integrates consume less energy, produce less waste, create a cleaner and safer environment for customers and produce better return on the customer’s investment as a result. Applications include feeding (school) children, delivering clean water, manufacturing recycled building materials, and feeding people’s pets. Projects resulted in less waste, less energy use, a cleaner and safer environment, and improved customer returns on investments. These are among successes achieved at NorthWind Technical Services leading to its selection at 2023 System Integrator of the Year in the $5 million to $30 million in system integration revenue category.

Michael Bosworth, president of NorthWind Technical Services, answered questions from Control Engineering and Plant Engineering (CFE Media and Technology) about control system integration projects and other enabling topics.

Question: Congratulations on receiving the 2023 System Integrator of the Year award: Talk about what this recognition means for NorthWind Technical Services.

One of NorthWind’s company goals is to be the recognized automation leader in the market segments we serve. Being recognized as System Integrator of the Year is a tremendous honor and validation that we are doing many things right. It is humbling to be recognized in this way as part of a very elite group of the best system integrators.

Question: Describe recent projects you’re most proud of. What has made them a success?

This is a difficult question to answer. During a recent Control Systems Integrator Association (CSIA) meeting I heard one of the companies talk about how they looked at what they did in terms of their impact on society and focusing less on programs, panels, and deliverables. That really struck a chord with me. When viewed that way, NorthWind is having a real impact on feeding school children, delivering clean water, manufacturing recycled building materials, feeding people’s pets around the world and many other really cool things. The control and automation systems we build have enabled our customers to provide these goods while consuming less energy, producing less waste in a cleaner and safer environment for their employees while producing a better return on the customer’s investment. Looking at NorthWind’s impact from that perspective is quite satisfying.

Question: What are some methodologies and philosophies applied to projects? How have they evolved?

NorthWind has more than 150 active projects at any given time. Our project delivery system and methodology is integrated into every aspect of NorthWind design, manufacturing, software development, and commissioning. At the core is our NorthWind PlantLogix family of customer-facing software, Eplan design software, and Project IQ enterprise resource planning (ERP) software. These systems all operate on one database that also integrates our automated panel manufacturing equipment and human-machine-interface (HMI) tag names. Project IQ ties all business processes together with project deliverables and scheduling. Collectively these systems work together to enable NorthWind to provide automation solutions that optimize cost, quality, and schedules in a way that benefits

2023 System Integrator of the Year

“

On-the-job training with a mentor for basic skills has been reinforced with intensive classroom training and learning including specific controls topics.“

everyone. In other words, we use automation within our own processes as well as providing that service to our customers. How we did things during and after COVID had to change because of the pressures of the pandemic. But, quite frankly, these changes have improved the way we do business. The future looks very promising for NorthWind.

Question: Have the supply chain issues affected current and future projects? If so, how?

Yes. Supply chain issues have impacted our panel manufacturing business and overall customer project schedules. We recognized the potential for problems early on and worked to increase our inventory to about five times pre-pandemic levels before the supply chain lead-time issues hit full force. We also began aggressively pre-ordering very early in the design phase of many projects to stay ahead of supply chain issues. Having good vendor relationships also helps a great deal in mitigating the impact of shortages. While these actions have not prevented all delays, they have helped us minimize the number of problems and enabled us to ship our panels in a timely manner.

Question: How do you help guide younger engineers?

Training and retaining employees is one of the top priorities for NorthWind and has been for years. NorthWind’s strategy for sustained growth over the last 25 years has emphasized hiring recent graduates and providing them with training needed to perform the work we do. What has changed in recent years is the training pace, structure, and content. On-the-job training with a mentor for basic skills has been reinforced with intensive classroom training and learning exercises. This is then followed up with more advanced multiday training classes on specific controls topics. Overall, this has really helped to advance professional development and reduce the time it takes for a new controls engineer to become productive.

Question: If there is one long-term goal you have for the company, what is it?

My overarching goal for NorthWind is that we always act as good stewards of the people and resources entrusted to us. We meet this goal by continuing to invest in our people, by challenging them to expand their knowledge through hands-on experiences, as well as through hard and soft skill training. For customers, we strive to provide an excellent return on their investments by the quality of the product we provide. That means striving to deliver innovative and reliable automation solutions that are up to date with the latest technologies making manufacturers as efficient as possible. We have done our jobs well and met this goal when employees, customers and ownership are all better off because of their associations with NorthWind. GSIR

Michael Bosworth is president of NorthWind Technical Services.

AT NORTHWIND TECHNICAL SERVICES, from left, Matt Lueger is vice president sales; Matt Bosworth is vice president manufacturing; Marlene Bosworth is executive vice president; and Michael Bosworth is president. Courtesy: NorthWind Technical Services

4 system integration metrics that matter

Each System Integrator of the Year firm for 2023 was asked to quantify recent progress using a few metrics. According to NorthWind Technical Services:

1. Recruiting and employee retention: We have successfully increased full-time staff by 24% in 2022 while maintaining a turnover rate that is about ½ that of industry averages.

2. Professional advisors include 2 individuals with extensive expertise in control system integration, business management and accounting; these advisors help with the business planning process, critiquing business practices and developing strategic plans for the future.

3. Projects for global good: 4 include positive impact on feeding school children, delivering clean water, manufacturing recycled building materials, and feeding people’s pets around the world.

4. Inventory in panel shop: 5x increase: To deal with supply chain issues we increased our inventory to about five times pre-pandemic levels before supply chain lead-time issues started.

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Rapid Transformation with Zero-Touch Edge Computing

System Integrator Successes You Can Learn From

Digital transformation is imperative for all businesses, and many organizations are turning to system integrators for innovative technology solutions to improve efficiency, performance, and safety. Zero-touch Edge Computing empowers the system integrator to be the hero for their end users, providing a solid foundation for project success, delivering unmatched reliability and rapid transformation of infrastructure.

With over 40 years of experience developing edge solutions that simplify, protect, and automate our digitally transforming world, Stratus is a trusted partner to SIs all around the world. From companies in oil & gas to those in life sciences or transportation, Edge Computing is a SI’s best friend. The customer success stories below prove it.

Edge Computing in Oil & Gas: Loginet and Petra Srl

Petra Srl owns and operates one of Italy’s largest oil depots, handling millions of liters of oil and gasoline and loading hundreds of trucks each day. To enable efficiency for depot operations, Petra runs Nuovo Petrol, a next-generation terminal automation solution from an experienced system integrator, Loginet.

With the Loginet solution and Stratus Edge Computing, Petra automated manual processes and integrated disparate terminal systems to reduce risk, enable real-time data, and centralize the visibility of operations. The company reduced depot load times significantly — by 33% — and has experienced zero downtime in a decade using Stratus Edge Computing.

“ Petra hasn’t had an unplanned outage in more than 10 years. They've never experienced any business disruption with Stratus as their foundation. When our customers need that extreme level of reliability, we will continue to rely on Stratus for continuous computing.”

Edge Computing in Pharma: RoviSys and Life Sciences Company

A leading life sciences company that manufactures cell biology, DNA, RNA, and protein analysis products needed to eliminate downtime and data loss in batch manufacturing to avoid costly disruptions and ensure regulatory compliance for the FDA, GMP, and VCAP.

In one week, RoviSys, a global system integrator specializing in automation, deployed Stratus Edge Computing platforms running Rockwell Automation PlantPAx® for three manufacturing sites. The new production control architectures provided fault tolerance, simplified validation, converged OT and IT, and reduced TCO by 15-20% compared to a cluster solution. The life sciences company has experienced no downtime and is able to service the Stratus platforms without dedicated IT support.

“ With Stratus’ longevity and durability, and streamlined FAT/SAT verification, our customer has a top performing, high-availability solution for the long haul.”

— Gianluigi Campisano, Automation Engineer, Loginet

— Network Engineer, RoviSys ADVERTISEMENT

Edge Computing in Transportation: Quantum Solutions and St. Louis Airport

As a major transportation hub for 30 years, the St. Louis Lambert International Airport is actively pursuing digital transformation initiatives to bring Industry 4.0 to aviation. Stakes are high for these modernization projects as they are crucial for consumer experience. Previously, projects had been piecemeal, disconnected, and limited to improving one area of the facility at a time.

System integrator, Quantum Solutions, used Stratus Edge Computing upon the recommendation of the St Louis Airport consultant to replace an aging and disparate building management system, enable continuous availability for critical business applications, and accelerate digitalization at the airport.

“ High availability is a big thing. When you're talking about moving an entire airport with multiple legacy siloed solutions over into one centralized system then you can't afford to have downtime.”

— Jeremy Meahl, Regional Sales Engineer and Owner, Quantum Solutions

Harness Opportunities at the Edge

Edge Computing is projected to become a $15B market over the next few years, and system integrators with the right skillset have the chance to tap into this rapidly growing market. According to a CFE Media/ Stratus Edge Computing Trend Report, fewer than 50% of organizations have the expertise of exactly how and when to deploy Edge Computing successfully. On top of that, Deloitte and MAPI shared, “more than 70% of manufacturers look to strategic partners to operationalize solutions”.

This is an enormous opportunity for SIs worldwide. Stratus designed a global system integrator program built around developing confidence, capability, and productivity to create scalable Edge Computing offerings for end users. Through the Stratus Global SI Program, system integrators gain the training, certification, and accreditation to develop Edge Computing technology practices that allow them to implement industry-leading Edge Computing platform solutions.

Not only does Stratus consistently receive feedback that they have delivered outcomes that exceed expectations, but the Stratus team has become trusted advisors to both partners and customers. Stratus ensures that their products and services continually drive partner and customer value and loyalty. Are you ready to learn more?

W2023

SI Giants average system integration revenue increases

ith more system integrators reporting, the average system integration revenue among SI Giants 2023 increased, compared to a year ago. 80 system integrators comprise the 2023 SI Giants, a ranking by system integration (SI) revenue for the most recently completed fiscal year, of control and automation system integration firms participating in the Control Engineering and Plant Engineering (CFE Media and Technology) Global System Integrator Database; 70 reported last time. This year’s table of 2023 SI Giants follows. Because it’s never the same set of SI Giants firms from year to year, data comparisons may mislead. Ten more SIs reported among 2023 SI Giants. Even so:

• In 2023, average system integrator revenue per system integrator reporting: $40.55 million.

Supply chain, staffing and COVID-19 are main concerns among SI Giant system integrators.

Top 5 “Biggest corporate challenge last year” among 2023 SI Giants

29% Supply chain issues, lead times

• In 2022, average system integrator revenue per system integrator reporting: $31.68 million.

Andritz moved into the top spot in system integration revenue. Second place RoviSys showed a double-digit gain in system integration revenue compared to last year. Some firms that fell in rank increased in revenue, and the highest and lowest ranked system integrators on the list also increased in SI revenue. Quad Plus moved to 3 from 6. Automation NTH moved to 23 from 27. Multi-Dimensional Integration moved to 27 from 29.

System integrator concerns, education

Research and data collection from the SI Giants includes views on corporate challenges and educational and mentoring topics. With evolving concerns affecting, the survey updated prompted replies. COVID-19 concerns and issues fell from 54 to 16% as the biggest corporate challenge, but a key component among those concerns was added in the most recent survey as its own choice and ranked highest. Supply chain issues, lead times at 29%. Staffing remained in second at 18%, though in a statistical dead heat with COVID-19 at 16%.

18% Staffing: Hiring, retaining, training employees

16% COVID-19 concerns and issues

13% The rising costs of automation system integration materials and equipment prices

13% The rising costs of automation system integrator labor.

Leading education and mentoring programs offered to engineering staff

88% Attend webcasts during business hours

86% Paid attendance to conferences/tradeshows

84% Formal internal mentoring (such as 1:1 pairing)

81% Paid training and testing leading to professional certifications

81% Purchase e-learning courses/materials

The survey included write-in questions. Some results follow. Click headline in digital edition to see more research results online.

What should an end user expect from a good system integrator?

1) Understanding we are in a partnership, collaborative alignment.

2) Provides feedback in a timely manner.

4) Makes work fun! GSIR

3) As a project moves forward our partnership becomes stronger.

Mark T. Hoske, content manager CFE Media and Technology, Control Engineering, mhoske@cfemedia.com; with input from Amanda McLeman, director of research and awards programs, CFE Media and Technology.

Baton Rouge, LA, USA

Taipei, Taiwan

Plymouth, MN, USA

Montgomeryville, PA, USA

Buffalo Grove, IL

McKinney, TX, USA

Grand Prairie, TX, USA

San Pedro Garza García, Nuevo León, Mexico

Marion, IA, USA

South Burlington, VT, USA

Clinton Township, MI,

Lynnwood, WA, USA

Wilson, NC, USA

nuclear,

Turkey

St. Charles, MO, USA

Louis, MO, USA

McKees Rocks, PA, USA

Digitally Transforming Ourselves GIANTS SYSTEM INTEGRATOR In Action

Randy Rausch, director of technology – digital transformation, Steve Orth, director of project management, EOSYS

Digital transformation is about using data to make better business decisions faster. The data shows agile project management methodologies consistently lead to higher quality, productivity and customer satisfaction.

Project development cycles that were acceptable 10 years ago aren't good enough for customers today. This trend will continue, and today's "fast enough" won't be fast enough tomorrow. To remain competitive, companies developing software need agile processes that navigate and harness the accelerating rate of change.

Agile helps teams develop better software faster and provides a competitive advantage in our rapidly changing world.

What is agile and how does it affect manufacturing operations?

Agile is a mindset and Lean manufacturing approach that emphasizes short time frames, adaptability and completing projects through incremental steps. Agile methodologies are often contrasted with traditional waterfall approaches. Gantt charts are replaced with burn up charts. Scrum masters and product owners play a key role in project execution. Learning and adapting are valued more than proving original estimates were correct. Customer collaboration is prioritized over contract negotiation. The highest priority in agile is to satisfy the customer through early and continuous delivery of valuable solutions.

Scrum is the most popular brand of agile and lightweight framework to organize, prioritize and execute projects with an emphasis on continuous improvement. Scrum is founded on empiricism and Lean thinking. Empiricism asserts that knowledge comes from experience and decisions should be based on what is observed. Lean thinking reduces waste and focuses on the essentials.

What are the internal benefits of using agile?

The scrum framework helps resolve certain scaling concerns while also enhancing quality and productivity. Beyond the financial benefits, there are significant benefits to employee engagement and developing younger talent. Agile promotes team autonomy, which leads to higher satisfaction. Small teams stick together to deliver a set of projects, giving early career developers regular access to more seasoned engineers. The team has a predictable, prioritized and well-defined set of features groomed and ready for development. The framework helps recruit “digital natives” and enables new employees to ramp up quickly and contribute, which reduces an unhealthy dependency on a few star employees.

What is your approach?

Driven by industry trends and customer feedback, EOSYS is focusing the use of agile within our Digital Transformation team. Starting with the selection of a software platform to support agile development, EOSYS implemented Microsoft Azure DevOps to support the new ways of working. We also invested in hiring a professional scrum master with the experience needed to help guide the team on its journey.

Responsible for guiding the project management practices across the entire business, Orth offers: We have been taking a methodical approach to this effort, one that we believe will result in long term success for our team and customers. Our ongoing efforts include benchmarking, training, and pilot projects with customers that are requesting agile project management. GSIR

EOSYS CREATES VALUE for our customers by delivering innovative technical solutions to automate, monitor, and secure their industrial systems, while anticipating future challenges they may face. Because we are an employee-owned company, our team members are personally invested in the success of each customer, recognizing its impact on the long-term success of EOSYS.

WE PARTNER WITH OUR CUSTOMERS to provide bestin-class solutions and services, delivered by employee-owners who are motivated by our customers’ success. Our methodology, dedication, and attention to detail generate lasting results.

INVESTED IN YOUR SUCCESS

MOST COMPANIES want you to think like an owner. At EOSYS we are all owners.

OUR HISTORY

FOUNDED IN 1991 as PREMIER System Integrators, we began as a provider of turnkey system integration services for manufacturing facilities in the southeast. Now more than 30 years later, we have expanded our service offerings, added locations and transformed into a 100% employee-owned company. In December 2021, we rebranded as EOSYS to better represent our ownership structure, recent growth, and path forward as a market leader in automation and information solutions.

us at eosysgroup.com

GIANTS SYSTEM INTEGRATOR In Action

The importance of focusing on cybersecurity for SI projects

Dan Malyszko, Vice President, Malisko

Cybersecurity has become more than a buzzword for manufacturers in recent years as more devices connect to the internet. This increased connectivity makes more devices vulnerable because they aren’t protected the same way a computer is. This means companies must be more vigilant and prepared for potential attacks. System integrators (SIs) can help manufacturers and other companies prepare with a thorough audit and plan during the project.

CFE Media: Has cybersecurity increased in priority in system integration (SI) projects?

Answer: We are seeing a larger IT influence on projects regarding cybersecurity, so things like control system access, role-based security, and industrial control system (ICS) asset identification are becoming more prevalent in operational technology (OT)-centric projects.

CFE Media: What are some of the biggest cybersecurity obstacles in SI projects?

Answer: Unfortunately, we still run into many industrial control systems with limited or no restrictive security access and authorization. At the same time, cyber- and data-security departments are trying to pursue zero-trust security frameworks. This issue is compounded by the information technology (IT) team’s unfamiliarity of the OT side of the house, so the overarching issue is alignment between these groups.

CFE Media: How do you help turn that challenge into a strength?

Answer: We have had high success with IT/ OT convergence by involving the right people from the customer and within our organization from the start. If a security conversation is not already happening, we broker a meeting with the customer’s IT and cybersecurity groups and gain credibility by having our

industrial network and security engineers present, to speak their language. Building trust with the enterprise IT and security departments is paramount to helping the customer achieve cybersecurity goals.

CFE Media: Has the COVID-19 pandemic changed the approach to cybersecurity?

Answer: Secure remote access to industrial control systems received a lot of attention from IT and security departments during the pandemic. This has been for the better because IT personnel have gotten to see some security struggles OT has had for years. IT can only help if they understand the unique requirements of ICS equipment and applications.

CFE Media: What has Malisko learned from the increased focus on cybersecurity?

Answer: Accurate asset inventory and a means to monitor network traffic in ICS environments are starting to become a requirement of many IT departments, and these directives are, many times, from the chief information security officer (CISO) or CEO. Increased media visibility on cyber-attacks in manufacturing has many stakeholders realizing they are, in many cases, years behind where they need to be with ICS security.

CFE Media: What other advice would you give about cybersecurity in system integration?

Answer: Be a champion for IT/OT convergence and help spread the message to the OT side of the house that IT folks can help. Embrace building relationships with the IT and security personas on the enterprise side to build trust. They will help you achieve best-in-class cybersecurity practices in the ICS environment, if you let them.

MALISKO is a CSIA Certified manufacturing automation solution provider with expertise in deploying Process Automation, Plant Floor Controls, Networks and Security, Computer System Validation, and Business Intelligence using IIoT Technologies for Asset Management, System Health Monitoring, Power Quality & Energy Management and Analytics.

OUR TEAM of engineers, designers, programmers and SME’s help clients safely increase production yield, reduce costs, and meet product quality requirements.

“Our automation core drives our innovation in the Industrial IoT.”

“WE EMPHASIZE asset visibility and control as the foundation of securing the plant floor.”

“We operate at the intersection of OT automation and Industrial IT to drive true digitalization.”

www.malisko.com

“Our automation core drives our innovation in the Industrial IoT.“

“We operate at the intersection of OT automation and Industrial IT to drive true digitalization.“

GIANTS SYSTEM INTEGRATOR In Action

Crafting a multi-faceted system integration strategy

Chris Vavra, web content manager, CFE Media

Increasingly, system integration projects require more than one specialty for success. In some cases, the integrator must employ the full breadth of their skills. RoviSys had a project where the customer required help in multiple arenas, pushing them to provide a solution that not only addressed all the customer requirements, but did so in a way that was streamlined and efficient. Brian Toler and Aron Friszman, group managers for RoviSys, discussed specifics about the project.

CFE Media: For this client project, they emphasized needing help with process control, building controls and information control. Can you explain a little more about the background about what they were trying to achieve?

Answer: To meet surging demand for its coatings and sealants (fueled by a COVID-19 construction boom), this Ohio based company needed to build a new production facility. The new facility features 90,000 sq ft of manufacturing space – including eight fully automated production lines as well as factory-of-the-future technologies. Full information and Industrial Internet of Things (IIoT) connectivity, as well as the capability to simultaneously mix eight different products and package them for shipment. Ultimately, the facility enables this manufacturer to quadruple capacity for production of sealants and waterproofing products.

The customer had a team of process engineers, but not a dedicated facility management team familiar with integrating facility support systems. RoviSys teams collaborated with internal stakeholders and delivered a single control platform across both the process control and facility control systems.

CFE Media: In terms of the three needs, which one did you feel you were strongest at or could most easily help the client in this project?

Answer: All three aspects, which is what makes RoviSys unique. The customer needed a process automation partner and master systems integrator (MSI) that would drive the design, selection and implementation of control systems utilizing technologies that optimize productivity, safety and efficiency. A consultative partner with expertise in both process automation and building automation. This exceeds the capabilities of a typical systems integrator (SI). For this $25 million Greenfield project, RoviSys also brought decades of boots-on-the-ground experience in the specialty chemicals industry.

History with this customer was in process control, with batch and historian/reporting. But RoviSys growth has been faster in information and reporting. Our building automation practice is state of the art, not the lowest common denominator. So, we offered an integrated solution to all needs at a competitive price and with a modern IIoT approach.

CFE Media: What lessons did you take away from this project that will be beneficial for future projects?

Answer: Basics of adhering to timelines, budgets and organizational planning were key to the success of this project, and will be for future efforts – especially those that that are collaborative efforts between RoviSys process automation & building automation teams. Take away was that a commitment and expertise consistently differentiate RoviSys. This customer has engaged with our teams to provide consulting and engineering services for their other facilities around the world.

ROVISYS automation and information solutions drive productivity, improve product quality, increase asset utilization and integrate technology. Customers turn to RoviSys for proven, reliable information management, manufacturing automation, control systems integration, building automation, warehouse automation, enterprise and industrial networks, MES, and Industrial AI. rovisys.com

CAPABILITIES

• Process Automation

• Building Automation

• Discrete Manufacturing Automation

• Warehouse Automation

• Control Systems Integration

• Manufacturing Execution Systems (MES)

• Industrial Network Solutions

• Building Management Systems

• Electrical Power Management Systems

• Analytics for Business & Process

• Electrical & Instrumentation Design

• Enterprise Networking

• Software Development

• Consulting

OFFICE LOCATIONS

NORTH AMERICA: Ohio, North Carolina, Texas, Michigan, Massachusetts, California, Georgia

ASIA-PACIFIC: Singapore, Taiwan, Indonesia, Malaysia

EUROPE: The Netherlands

Matt Boyer, CCST, Tesco Controls

Support for water/wastewater facilities

As water/wastewater municipalities are struggling to replace retiring technical personnel and support increasingly sophisticated automation technologies, they are finding well-staffed system integrators can provide needed electrical, instrumentation and controls support.

Municipalities are facing a multitude of challenges on how they operate their water and wastewater systems. These challenges include new regulatory standards, complex treatment processes, environmental scarcity and population-driven increases in system demand. Other compounding issues to contend with include the need to incorporate continuing advancements in technology like smart instrumentation and final control elements as well as the struggle to replace retiring operators and control technicians. These aspects exacerbate already complex requirements water and wastewater facilities face for calibrating, maintaining and troubleshooting their equipment (Figure 1).

However, these challenges can be addressed by systems integrators (SIs), who can help by providing contractual preventive maintenance, calibration and troubleshooting services. SIs help relieve the burden to keep production systems online by complementing the municipality’s staff capabilities while filling gaps in staff numbers and/or expertise.

SI support system

For many years, municipality staffing levels and skill sets—especially for simpler system designs—were sufficient to handle most issues. Basic operations used pressure, level, flow and other process instrumentation to control pumps, valves and other automated equipment. Today’s systems and technology are increasingly digitized and more sophisticated to deliver improved performance, but often with greater complexity to design, deploy and operate (Figure 2).

Municipalities benefit from hiring and retaining staff who are multidisciplined. Technical staff must understand smart instrumentation, networking, radio telemetry, supervisory control and data acquisition (SCADA) application development, human-machine interface (HMI) configuration, programmable logic controller (PLC) programming and electrical control components setup. This is on top of the basic electrical, mechanical and safety skills that were always required. Finding and keeping these workers has

become more difficult, as the existing workforce is “graying,” and new workers often prefer remote work options.

Many SIs offer post-startup services on the specific systems and equipment they were involved with. Responses typically were on a case-by-case basis after an issue arose, requiring troubleshooting and repair at a level beyond what onsite technical staff could handle. This work was often invoked at a moment’s notice and billed at time and material (T&M) rates.

Acknowledging the flaws of this approach, some larger SI firms have developed contractual solutions— usually in the form of annual, bi-annual, or multi-annual contracts—based around preventive and extended maintenance solutions. This approach enables SI

FIGURE 1: Water/wastewater municipalities, and processing operations of all types, face many challenges with adopting innovative technologies, supporting increased digitalization, and replacing retiring workers. A full-service SI can provide the sustaining support they need. All images courtesy: Tesco Controls

Sustaining SI support for water/wastewater facilities

FIGURE 2: Industrial automation has advanced far beyond traditional methods in both capability and complexity. An SI is in the business of assembling an entire team of multidisciplined staff to support all aspects of designing and maintaining today’s electrical, instrumentation, HMI/SCADA, and PLC systems.

Onlineu

KEYWORDS: system integrator, system integration projects

LEARNING OBJECTIVES

System integrators can help with control system, automation and instrumentation projects. Maintenance project help also is available.

ONLINE

Click headline in digital edition to see more online about help with instrument calibration, automation maintenance services and SCADA maintenance tasks.

CONSIDER THIS

What automation projects do you need help doing?

FIGURE 3, COVER: As part of a complete service contract, an SI can perform HMI/SCADA maintenance and resolve a wide range of issues during normal visits, without requiring special projects to be initiated.

staff to work on control panels, motor control centers (MCCs), variable frequency drives (VFDs) and other automation to monitor system health, identify potential problems and points of failure, and proactively mitigate issues before they cause shutdowns.

Service contract options

Complete service contracts, which include provisions for SIs to investigate control and electrical panels, can yield significant savings by reducing outages. For example, these investigations frequently identify failed uninterruptable power supplies (UPSs), discover dead PLC backup batteries, and find broken cooling fan and thermostat devices need-

ing replacement to protect equipment from hotter summertime temperatures (Figure 3).

These issues do not always annunciate conditions in ways operators notice ahead of time. However, operators would certainly become aware of the situation in the event of a power failure or heat wave, which can take down system devices and equipment, potentially resulting in downtime, delayed restart time, and program and memory loss.

By engaging a well-versed system integrator from outside the municipality to routinely inspect control panels, facilities can significantly mitigate potential points of failure inhouse operational staff may not notice while focusing on day-to-day issues.

Beyond control panels, some clients choose to have SI support teams inspect electrical equipment, as well. MCCs are industrial-grade electrical hardware, but they are often overlooked by operators who believe that if equipment is running, then all must be well. A prepared SI can scrutinize operational MCCs with voltage and amperage checks, and in some cases use power quality analyzers to identify possible utility power issues (Figure 4).

A thermal imager is another helpful diagnostic

FIGURE 4: SIs with appropriate training and skillsets can support electrical instrumentation and controls.

device that a municipality might not have on-hand. Thermal imagers are used to perform infrared (IR) scans of electrical components and terminations—MCCs, VFDs, soft starters, contactors, and transformers—a while in operation to identify loose connections or failing components. A simple retorquing activity can prevent a lost-time failure event from loose connections.

Infrared scan sees loose connection

For example, an SI was performing IR scans at a municipality as part of its preventive maintenance program, and they found a loose connector on the breaker feeding a VFD. While the VFD was still in operation and appeared to be working normally, the scan showed one of the three conductors on the load side of the breaker was 100oF hotter than the other two.

The staff was able to safely power down, lockout/tagout (LOTO) the drive, and properly remedy the connection. This solved the temperature issue, preventing operational and safety problems that could have occurred later if not addressed.

Process instrumentation support

Only some SIs are equipped to perform electrical support services, but a greater number can provide instrument calibration and verification support (Figure 5). Many sites have hundreds or thousands of field instruments of varying vintage, make and model. These often require annual attention to confirm and document proper operation, communication, scaling and interaction with PLCs and SCADA.

While instruments usually are dialed in during startup and commissioning, process and environmental conditions change over time and instrument drift occurs causing errors. If flowmeter was replaced but configured with incorrect scaling, the SCADA system could under-report total process flow. GSIR

Matt Boyer is the extended maintenance and system services (EMASS) supervisor at Tesco Controls.

FIGURE 5: Considering that a typical municipality or processing plant uses hundreds or thousands of field instruments requiring periodic calibration and inspection, many end users rely on the support of a full-service SI to supplement their in-house staffing.

Michael Horth, Applied Manufacturing Technologies

Custom algorithm used to solve challenges with robotic layer forming and de-tray system

AMT and Gojo Industries Inc. worked together to create two robotic cells to function in part with their conveyor system, a de-tray operation and a layer forming system.

Awww.controleng.com

KEYWORDS: machine vision, discrete manufacturing CONSIDER THIS How can 3D vision improve your manufacturing operations?

ONLINE Click headline in digital edition to see more project details and images online.

pplied Manufacturing Technologies (AMT) worked with Gojo Industries to create robotic cells: a de-tray and layer forming system. To aid in vision issues on the detray system, they used 3D snaps, which is a method that generates 3D point cloud. Engineers restricted the movement of the robots to help increase its speed. On the layer forming side, engineers used a camera above the conveyor so that any box can get through. To solve the speed issue, the conveyor used its rails to align boxes and increase speed.

The robotic de-tray system was set up to receive trays of product (one-layer, homogenous SKU). A database supplied information about each tray, including the box length, width, height, weight and expected orientation, as well as how many rows and columns make up a single tray. Using an overhead 3D vision system and programmable logic controller (PLC) to find all the boxes on the tray and a custom algorithm

to determine which boxes to pick up, the robot arm moves to the target boxes, uses a vacuum gripper to pick them up and moves to an outfeed lane to drop them off. Boxes must leave the machine in single file with their length along the conveyor flow direction.

The robotic layer forming system receives individual cases from a metered infeed conveyor lane along with a set of data describing each box. An overhead 2D camera finds each box on the conveyor as it comes in. Using an encoder that measures the motion of the conveyor belt, the robot moves a gripping tool around each incoming box, squeezes to hold it and moves it on the conveyor belt so that together with the other boxes on the conveyor, it will form a grid pattern at its destination.

Solution: Vision system, motion control

In-depth research was conducted on the capabilities of the 3D vision system and learning about using it to find rectangular boxes. This vision system uses a off-the-shelf software called box locator tool. Depending on the type of load parameters, the robot’s speeds and accelerations had to be adjusted to handle loads with diverse conditions, orientations, weights and heights. The rail was referenced as a baseline location and three rows of boxes were placed in the proper position to form the required pattern at the end. Since one-third of the boxes came onto the conveyor properly positioned at the rail, only two-thirds needed to be moved, saving time and meeting the 1.1 second throughput requirement without putting the robot above its sustainable capacity.

In designing the de-tray and layer forming robotic cells, the engineers solved several high-level technical challenges, including writing a new program for the 3D vision system and creatively solving robot speed issues to meet cycle time requirements. GSIR

Michael Horth is a senior controls engineer at Applied Manufacturing Technologies, a CFE Media and Technology content partner.

FIGURE:

Christopher Rudd, Rayn Business Development; Randy Otto, ECS Solutions

Integrating a DCS into an existing process cell

A distributed control system (DCS) needed to be installed in a process cell for a pharmaceutical company, but the process required an overhaul to the systems and standards in place to make it work.

Apharmaceutical company was in the process of commissioning a control system for a process cell and asked ECS Solutions, a system integrator, to provide site support to complete the commissioning and qualification.

The control system supplier had taken a simplistic approach to keep costs down. One controller with multiple human-machine interfaces (HMIs) provided the heart of the control system that also interfaced with some original equipment manufacturer (OEM) skids. The control hardware consisted of a controller with multiple HMIs. The controller code was all custom with little use of off-the-shelf products and was an assortment of custom blocks of code tied together, providing minimal functionality.

Sequence, procedures, documentation

Little thought had been put into operators and how they would run the system to create quality product. Standard operating procedures had not yet been developed. Producing a quality product was dependent upon the operator selecting the correct sequence of functions from operator stations at multiple vessels. This approach exposed the company to risk in producing a quality product and controlling the rate of production.

Since procedures had not been considered to this point, the system was not well documented and inevitably in store for substantial changes through the commissioning and qualification phases of the project.

As the owners started to think practically about how operators would make product, change requests started pouring in. Changes to the custom logic were challenging. It was difficult to determine what effect small changes would have in other areas of the program. The integrator evaluated the situation and recommended a migration to the control system, providing batch software for the batch automation with process objects in the controller replacing much of the custom code.

Work progressed including procedural control, parameter transfers, data gathering; Creation of an

equipment model, phase classes and phases; and a global standard library with standardized objects.

Changing role for control system integrator

The integrator’s role in the project changed as time progressed. Initially, the aim was to put a wrapper on the existing code and not modify it, that is, the original agreement with the company. Subsequently, it was decided to make changes to improve the system, due to the lack of required functionality, and today the company can make extended batches, considered to be active production batches while the product awaits FDA approval.

The batch software also has enabled a wealth of historical data to be logged in the form of batch records and reports, including electronic signatures. The modification has allowed the company to maximize the utilization of its equipment. Using a feature in the batch software, electronic prompts allow operators to review and respond, including provision of detailed photographs of equipment setup for operators’ absolute activity clarity.

Using the software suite recipes to drive cleanin-place (CIP) processes simplified the use of the CIP system and established repeatable consistent cleaning cycles that provide as much insight as product batches. This accelerated the commissioning and validation of those systems. GSIR

Christopher Rudd, CEO, Rayn Business Development; Randy Otto, CEO, ECS Solutions.

Process manufacturing Insights

u A pharmaceutical company wanted to integrate a control system into an existing process cell, but an overhaul of the process was needed to make this work.

u A wrapper logic was created in phase manager phases to allow the software suite to control the existing equipment models and sequences.

u A Rockwell Automation PlantPAx Solution was integrated with FactoryTalk Batch software suite from Rockwell Automation, including key procedures and direct signatures for a system integration project involving a pharmaceutical manufacturer. Reports are created in Infobatch by Informetrics Systems Inc.

Answers More u www.controleng.com

KEYWORDS: system integration, batch manufacturing

A pharmaceutical company commissioned a control system for a process cell, but needed a system overhaul. Migration provided the necessary functionality, qualification and validation. ONLINE

Click headline in digital edition to see more online for more on:

Procedural control, parameter transfers, data gathering

Equipment model, phase classes, phases

Global standard library, standardized objects

https://www.controleng.com/ system-integration/ CONSIDER THIS

Have overhauled your control system with positive results?

Karen Griffin, PE Hargrove Controls + Automation

Retrofit project for biodegradable plastics facility

A bioplastics company contracted a system integrator to retrofit a brownfield plant to make Nodax polyhydroxyalkanoate (PHA)-based resins, adapting existing on-site batch controls.

Danimer Scientific is a bioplastics company focused on the development and production of 100% renewable and biodegradable plastics and adapted brownfield site to upscale a lab process into a full manufacturing plant, adapting existing batch controls. Made from Nodax polyhydroxyalkanoate (PHA)-based resins, these compostable polymers can replace single-use plastics in sustainable products. The product has interest in the food and beverage industry as a replacement for traditional plastics that end up in a landfill and can take over a hundred generations to degrade.

Moving from pilot to production facility

Images courtesy: Hargrove Controls + Automation

Early in the development of the company’s patented new biodegradable plastic technology,

Danimer Scientific partnered with Hargrove Controls + Automation to help upscale an R&D laboratory process and a small pilot line to a production-scale manufacturing facility.

“When we first partnered with Hargrove in 2015, we started working on making a production-scale facility for PHA, and we were the only ones doing this,” said Daminer Scientific’s COO Michael Smith. “The information didn’t exist on how to turn this laboratory hypothesis into a manufacturable process.” The system integrator helped“develop the technology and basically invent a new process. We were ‘writing the book’ for the world’s first PHA plant. We relied heavily on Hargrove for the design and automation functionality for a future greenfield facility’s design. We knew roughly how we wanted to make the product, and didn’t know what it was going to cost.” The system integrator “designed a facility so we could start raising money.”

Danimer found an existing facility that could be retrofitted to make PHA. The company purchased an 88,000-sq-ft brownfield plant in Winchester, Ky. to convert into the operating facility to repurpose and retrofit the facility. The manufacturer relied on the system integrator to guide the process, Smith said.

Automation scope, 4000 I/O

This project held many challenges. As the first operating facility for this product with no full-scale pilot, the team needed a solid plan with buy-in from all key stakeholders. In addition, the project needed to meet the budget demands of a startup technology company and navigate pandemic-induced supply chain issues. The phase 1 retrofit total investment cost was $55 million, for a total $175 million. The automation scope had more than 24,000 human-hours and over 4,000 input/output (I/O) points. It included narratives and specifications, multiple complex batch operations developed for upstream and downstream processes, tying new equipment into the existing facility, skid package interfacing, wireless network development, historian, site support, commissioning and operator training.

FIGURE 1: The world’s first PHA plant, Danimer Scientific in Winchester, Ky.

Retrofit design, DCS, HMI

The facility is controlled by a distributed control system (DCS) batch system upgraded to the latest operating system and includes a human-machine interface (HMI) rebuild and operator interface. There is a plant-wide data historian which gathers information from the DCS. There are nearly a dozen third-party skids integrated together into the DCS, which was a significant part of the effort. Many of the skids are on the finishing unit, which takes the output of the clarification and sends it to the centrifuge, dryer, and pelletizer.

“What made this project challenging from a technical standpoint is that it’s a hybrid process,” said Joshua Payne, operations leader at Hargrove Controls & Automation. “It’s a mix of biotech, pharmaceutical, and life science technology mixed in with the heavily batch-oriented processes of a chemical plant.” Payne continued, “Hargrove helped Danimer with due diligence on the Kentucky facility, making sure it was feasible to buy and use for their process. We engineered the conversion of the facility and engineered the automation.”

The existing facility had a batch control system, which was reused for the new application, said Alan Polk, technology & innovation leader at Hargrove Controls & Automation.

Integration, expansion, PLC

The system integrator’s efforts mainly focused on the fermentation and clarification parts of the original process, which included three small fermenters, clarification/purification, dryers, and a programmable logic controller (PLC) skid-based pelletizing system. Because of increased customer demand, Danimer decided to expand the new facility by tripling the capacity. This required more fermentation and down-stream processing equipment. The system integrator was asked to bring in two additional large fermenters, each more than twice the size of the original units, nearly tripling the fermentation capacity. As expected with a retrofit project, Polk noted there were several technical challenges while bringing the Kentucky facility online. “Many of the project’s challenges were from turning

an R&D process from a laboratory environment into production scale. The selected facility had been mothballed, so the existing documentation was inadequate and the existing equipment was not what it appeared to be when the design was created,” he said. “We were trying to engineer a capacity increase on a system that was in an unknown state and had undocumented changes.”

Polk said, “This is a new process that no one has ever run before, so Danimer scientists were often making modifications. Polk said engineering continued on a triple-increased capacity project while Danimer was researching, testing, and modifying, while the system integrator ensured new change

Bringing the Kentucky facility online was a very schedule-driven project, which was a constraint as well as motivator. Payne said, “We’re going to do everything to get this done as quickly as is reasonably possible while maintaining our safety and quality standards.” Project included efforts to keep the design lean and costs low, while developing control schemes using good control theory integrated with equipment knowledge and use of emerging automation technology in the first PHA plant. GSIR

Karen Griffin, PE, is vice president of Hargrove Controls + Automation, a CSIA Certified Member; CSIA is a CFE Media and Technology content partner. Edited by Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.

KEYWORDS: chemical manufacturing, system integration

LEARNING OBJECTIVES

Danimer Scientific partnered with Hargrove Controls + Automation to help bring their R&D laboratory process online by retrofitting an existing facility in Kentucky. A lack of documentation and technical challenges caused problems during the retrofit. High demand for the company’s resin product caused deadline challenges. ONLINE https://www.controleng.com/ system-integration/

CONSIDER THIS

Have you done a retrofit while applying a new process?

FIGURE 2: The Danimer Scientific facility in Winchester, Ky., is controlled by a DeltaV DCS batch system and uses a DeltaV Live operator interface also from Emerson.

FIGURE 3: Nodax PHA is produced from readily available feedstocks and is 100% renewable.

Travis Cox, Inductive Automation

HMI/SCADA systems: Upgrade your migration

When upgrading human-machine interface (HMI) and supervisory control and data acquisition (SCADA) software, use five tips for optimizing HMI/SCADA screens.

Wwww.controleng.com

KEYWORDS: HMI, SCADA, control system

LEARNING OBJECTIVES

Provide a clear information flow to the user.

Take advantage of mobile flexibility.

ONLINE

Click headline in digital edition to see more online on how to standardize the SCADA system in an upgrade; taking a holistic approach to migrations; and new SCADA capabilities after an upgrade.

CONSIDER THIS

Get the most from your HMI or SCADA upgrade.

hen organizations plan to upgrade software for human-machine interface (HMI) and/or supervisory control and data acquisition (SCADA), a lot of questions accompany the migration project. Where do we begin? What do we keep, and what do we toss? Which HMI screens need redesigns? All these questions are important, but another key factor is understanding users can do much more than a simple upgrade with new SCADA and HMI software. Why not go beyond that, and take the opportunity to make changes that will provide several significant benefits for a manufacturing company or process facility?

Five tips for optimizing HMI/SCADA screens

When switching vendors, there’s no “easy button” that converts everything. Even if there were, you'd want to address five areas in a screen upgrade:

1. Determine the navigation structure of HMI/SCADA designs. In any HMI/SCADA application, good navigation is vital. Pick a layout that helps operators get to relevant data quickly and effectively. Should navigation go broad and shallow, or narrow and deep? Think about primary and secondary top

headers. Do you want side navigation? Will you use tabs? All of these could be an ideal choice, depending on the complexity of display needs. Many of these can be used in combination.

2. Reduce HMI/SCADA screen cognitive load for the user. Cognitive load is the effort required by the user to get a mental map of how a system works. The human brain can only process so much information at one time, so the interface should emphasize what’s important and get rid of extraneous information. Remove visual clutter, use neat alignment and grids and use only two or three fonts or font variations. To help users quickly absorb information, pair icons with text.

3. Create HMI/SCADA visual hierarchy. This helps users quickly recognize what information is most important. Emphasize the important elements by varying size, position, color and isolation.

4. Use high-performance HMI techniques. These types of designs and displays help the user make the best decision in the shortest amount of time. High-performance HMIs often use grayscale rather than traditional graphics and bright colors. If flat graphics are used, and most of the screen is gray, it’s easier to draw the user’s attention to the most important information. The user’s eye will be drawn to an item in red or orange. Beyond color, certain graphic techniques help contextualize data for the user. These include sparkline charts, moving analog indicators and radar charts.

5. Leverage HMI/SCADA mobility. Everyone expects to receive data on phones and tablets. With mobile-responsive design, companies can design the screens once and it will resize and reformat perfectly for any device being used. Mobile devices also have powerful features that can be used such as GPS, camera, Bluetooth LE, NFC and more. Users also can use the cloud for deploying read-only applications. GSIR

Travis Cox is co-director of sales engineering at Inductive Automation, a CFE Media and Technology content partner. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

FIGURE: High-performance HMIs use plenty of gray, making it easy to see alerts and alarms in bright colors. Courtesy: Inductive Automation

Benson Hougland, Opto 22

Leveraging MQTT, industrial edge devices

Message queuing telemetry transport and industrial edge devices help IIoT implementations.

With the Industrial Internet of Things (IIoT), the goal is to get useful data from field devices and legacy systems and move that data where it’s needed–for asset management, for regulatory reporting, for efficient maintenance, for making business decisions. Assembling an IIoT system is often complicated, involving many operational technology (OT) and information technology (IT) devices, protocols and software. System integrators are finding that two tools can simplify IIoT implementation: the message queuing telemetry transport (MQTT) communications protocol and industrial edge devices.

MQTT (formerly IBM’s MQ Telemetry Transport) is a publish-subscribe (pub-sub) protocol originally developed for the oil and gas industry. Pub-sub reduces connections and network traffic. Each client initiates communication to a central broker/server and then publishes data, subscribes to data or does both.

The broker/server accepts and forwards data packets as required. Network traffic is reduced because data is communicated on a report-by-exception (RBE) basis rather than at regular intervals. Industrial edge devices are designed to withstand harsh industrial conditions and act like a PC in many ways. They communicate using OT and IT protocols. Three system integration (SI) IIoT implementation projects follow.

Wastewater, natural gas, vision

Waterford Township has shared data among water/ wastewater core applications such as geographic information systems (GIS), asset management systems (AMS), enterprise content management (ECM), and supervisory control and data acquisition (SCADA). To upgrade, they chose an edge controller because of its built-in MQTT capabilities, familiar programming tools, and lifetime I/O warranty. They decided on a SCADA software with MQTT integration, including ability to serve as an MQTT broker. The controller’s MQTT infrastructure has reduced field updates from multi-minute cycles to sub-second event-driven publications. With that speed, Waterford never misses a system action or alarm notification.

Dan Arbeau, CEO of netDNA in British Columbia, said a customer, New Wave Energy Services, needed help in Southern Texas, managing water at

hundreds of drilling sites. New Wave designed large trailer-mounted units for water transfer, typically with four 500-800 HP pumps with 12-in. diameter inputs and turned to netDNA to automate them. Edge controllers publish data to the MQTT broker, and other edge controllers subscribe to the data. For the broker, a hosted secure MQTT server was used.

California-based Intrinsics Imaging offers customers machine vision systems with machine vision software. Instead of programming specialized cameras to inspect for defects, the machine vision software works with any IP camera. Edge I/O had an industrial build, a Linux core and multiple options for MQTT. For security, Intrinsics built an isolated network at the customer’s facility to connect cameras and edge I/O modules to an on-premises MQTT broker. A separate network connects that broker to the internet for video streaming to the machine vision software and data exchange with a cloud MQTT broker. Both run on Amazon Web Services (AWS). GSIR

Benson Hougland, VP of marketing and product strategy, Opto 22. Edited by Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.

KEYWORDS: message queuing telemetry transport, edge computing, IIoT MQTT and industrial edge computing devices can help get information to users faster.

Three IIoT examples of MQTT and edge devices in different industries are highlighted. Cybersecurity and data protection are considered as vital as getting the information to the users who need it most.

ONLINE

Click headline in digital edition to see more online about three applications and two more photos.

CONSIDER THIS

Have you used MQTT and edge computing in your facility and what were the results like?

FIGURE: One of Waterford DPW’s lift station control panels, showing the new layout with the Opto 22 groov EPIC controller and DIGI modem. Perceptive Controls helped. The water/wastewater utility chose the groov controller because of its built-in MQTT capabilities, familiar programming tools, and lifetime I/O warranty. Courtesy: Opto 22

Nikhil Niphadkar, Patti Engineering

Model management software challenges at automotive facility

A system integrator was tasked to dig through model management software and create a new system for an automotive plant using intelligence from PLCs and HMIs.

Introducing new production models is a regular occurrence in the automotive industry, but for a local transmission manufacturer, this change became a complicated process. The new subcomponent model required the production lines to use a longer model number. The existing model management software had a user-friendly front end, but the back end was full of hard-to-follow code and lacked descriptions or documentation. Several plant engineers had attempted to work through the code, but were unable to make any progress.

The manufacturer reached out to Patti Engineering, a system integrator, to dig through the black box software, decipher how it worked and determine the best approach to make the necessary updates.

Complex code, no documentation

www.controleng.com

KEYWORDS: Models for automotive production, HMI, PLCs

LEARNING OBJECTIVES

Lacking documentation of how things work, observing programmable logic controllers and humanmachine interfaces can help update production models.

Updated code was applied to a pilot station, then the main line.

ONLINE

Click headline in digital edition to see more online about benefits and PLC and HMI observation, along with two figures showing code.

https://www.controleng. com/control-systems/ plcs-pacs/ CONSIDER THIS

Is your documentation up to date?

The model management system used only the first 13 characters to designate the transmission instead of the entire 15. The new models would now require all 15 characters, which affected several production lines.

An original equipment manufacturer (OEM) had written the management system software years ago and did not provide documentation on its functionality. The plant engineers had not progressed

working through the complex layers of code and could not answer any questions about it. As it was written using instance data blocks, even a small change had the potential to break the code and take down a station. Special care was needed to keep the production process functioning, the reporting software accurate, and allow the station to accept the new model type. This project required a lot of planning to coordinate the rollout of the new code. The changes affected all existing models. The most affected production area was the secondary line that worked with the subcomponent exclusively. Every station required the standard changes with significant updates for load in, load out, laser etching and camera verification stations. The main line also needed to be updated for the subcomponents to be loaded in successfully.

As production ran all week, the only time for testing and validation was on the weekend. Delaying production was not an option, so all changes had to be removed at the start of every week until the plant engineers validated all changes.

The combination of originally unplanned trips greatly reduced the overall project risk and created a great baseline to ensure project success. During the project, the integrator documented all the required changes they had made and then trained the plant engineers on the management system. Plant engineers used the notes to complete main line updates.

The integrator returned onsite when new code was launched in tandem with the main line. They watched alongside the plant team as the model management system successfully ran old and new parts. GSIR

Nikhil Niphadkar is senior controls engineer at Patti Engineering, a CFE Media and Technology content partner.

FIGURE: Siemens Simatic manager view shows the types of blocks involved in the project. Courtesy: Patti Engineering

Matt Cingcade, RoviSys

Reducing scrap and risk at plastic facility

A leading plastics manufacturer needs a full, top-to-bottom technological makeover to update obsolete systems, improve efficiency and reliability, while reducing scrap and inaccuracies.

Aglobal acquisition provided a Missouri-based plastic bag manufacturer the opportunity to upgrade its legacy controls and information infrastructure. The goal was to create a state-of-the-art, data-rich system that was up to the challenge of modern manufacturing.

The plant requires precise timing throughout every step of its manufacturing process to keep product flowing. Any interruption in the process results in hours of downtime and requires manual intervention for equipment cleaning and system reset. Plus, incomplete batches are problematic, and effect customers downstream.

The legacy control system that had been running this process required continual operator interaction, resources and operator-hours to run. In this manual-labor heavy environment, inventory reconciliation was consistently 15 to 25% off, and the company was unable to consistently calculate the scrap that resulted.

To bring operations up to date, the company needed a system integrator with expertise to take on a massive overhaul of a supervisory batch implementation with a requirement for real-time, on-time delivery of product. After exploring the market and experimenting with integration competitors, the manufacturer found an integrator with industry knowledge, extrusion and batch processing experience with large-scale migrations. The system integration project included automation and assessing the existing system, gathering of project requirements, providing design guidance and strong project management to ensure that the final solution met the working group’s needs.

Two-part control system upgrade

The enterprise-wide nature of the effort made the initial assessment phase critical. First steps of requirements gathering, problem identification, site survey, interviews, and collecting information set up a foundation to build the right solution. All stakeholders were interviewed: global IT personnel, operators, plant floor staff, supply chain and raw materials experts, maintenance workers and managers. Using interview

information and other information, a two-part comprehensive plan was developed.

1. Process control: The integrator crafted a supervisory batch solution around the challenges of the fast-paced resin delivery system, comprised of many shared pieces of equipment. Modern fault tolerant network topologies, connected devices, and distributed I/O were deployed to create a solid basis for robust operations and to enable continuous information flow. Leveraging the plant floor’s infrastructure and the simplicity of the ISA-88 model, the integrator established an efficient and straight forward means for the convergence of the plant floor real time data with the enterprise resource planning (ERP) system.

2. Information flow: The integrator designed and developed a data communication protocol using XML and RESTful web services to receive production orders, recipes and inventory data from the company's ERP system. Inventory consumption data from production would be automatically reported back to the ERP system to allow for accurate inventory tracking without user interaction.

Modernization project results

Once each component of the modernized solution was tested and ready, the integrator worked directly with the plastics manufacturer to roll out the solution with as little disruption as possible. A five-day window was allotted to get the first production line operating. The integrator was able to bring the first line up in just three days, and within five days, five out of six of the total lines were running on the new system.

With the solution in place, the plastics manufacturer saw quick resolution of its key issues. There was complete visibility into overall manufacturing process with traceability to each individual material in every batch. Legacy components also had been eliminated, which reduced the risk of potential downtime due to obsolete parts and manual intervention. GSIR

Matt Cingcade is director, chemicals and specialty chemicals, RoviSys. Edited by Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.

KEYWORDS: process control, enterprise resource planning, ERP LEARNING OBJECTIVES

A plastic manufacturer wanted to overhaul their legacy control system to reduce inefficiencies and waste.

The system integrator chosen for the project improved process control and information flow to provide real-time data through the enterprise resource planning (ERP) system.

The results were improved visibility in the manufacturing process and less need for manual intervention.

ONLINE

See additional case studies at https://www.controleng. com/case-studies/ https://www.controleng. com/articles/ eight-iiot-project-tips/ http://www.rovisys.com/ CONSIDER THIS

What challenges can you overcome by upgrading a legacy control system?

Dino Busalachi, Velta Technology

Removing IT/OT barriers to ensure plant floor safety, operational integrity

Securing industrial control systems (ICS) differs from protecting enterprise networking and information technology (IT) and operational technology (OT) teams must collaborate as cybersecurity threats rise.

The convergence of enterprise network management and industrial equipment management due to the Industrial Internet of Things (IIoT), Industry 4.0 and industry-wide digital transformation requires that operational technology (OT) and information technology (IT) teams collaborate on cybersecurity and industrial automation equipment safety.

Five day-to-day strategies to help IT, OT

1. IT and OT involvement in production cycles

www.controleng.com

KEYWORDS: IT/OT convergence, plant safety LEARNING OBJECTIVES

Information technology (IT) and operational technology (OT) departments need to work together to keep industrial control systems (ICSs) secure.

Communication and collaboration are key to lowering barriers between the two sides.

Establishing firm boundaries and set roles can help reduce confusion.

ONLINE

Click headline in digital edition to see more online on IT safety; cybersecurity; OT safety; removing the barriers to improve; how IT, OT can learn from each other.

CONSIDER THIS

How are IT and OT collaborating at your facility?

IT should be part of the planned and scheduled maintenance routines and learn common safety practices including how and why certain rules apply. They should understand full production cycles from line and product changeovers to seasonal production activities.

2. IT and OT decision-making

IT should be invited to be part of all decisions relating to automation technology. If OT teams are pursuing lifecycle, expansions or upgrades, IT should be part of the process at every step. IT should review the technology decisions related to ICS infrastructure and networks including technology choices, architectures, service & support agreements.

3. Third-party involvement: IT, OT knowledge

IT should know how third parties are engaging with the OT network in relation to maintenance and support of ICS equipment. Third-party network connections through ICS equipment can impact enterprise safety.

4. Asset visibility for IT, OT

Get an accurate, up-to-date ICS/OT inventory and a documented list of all common vulnerabilities and exposures (CVE’s) for each asset. This can be achieved by deploying a continuous monitoring platform that tracks the ICS digital footprint. New activities in the

ICS environment need to be understood and captured. Unplanned and unscheduled downtime should be documented, response and recovery should be known. PLC changes should never go unnoticed.

5. Parallel reporting for IT, OT, ICS

Reporting should run parallel. If IT is reporting on IT system performance, they should apply similar roles and activities in relation to ICS on the OT side of the business. Digital functions related to ICS equipment need to be captured, traced, logged, audited and baselined with no exceptions. The same incident and response to a safety issue cannot go unnoticed, undocumented or ignored. If someone is hurt or killed or serious damage is caused, everything stops to determine whether or not processes, policy and procedures were followed to find the cause. GSIR

Dino Busalachi is chief technology officer and co-founder of Velta Technology, a CFE Media and Technology content partner.

FIGURE: Industrial control systems (ICS) cybersecurity is the responsibility of the information technology (IT) and operational technology (OT) teams. Courtesy: Velta Technology

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Our clients benefit from this culture that loves working together; committed to reliability and responsiveness. Thousands of integrators and users around the world experience our knowledge of how industrial software can work together through our ability to work patiently with multiple vendors and customers.

Visit us at info.softwaretoolbox.com/integrators to learn more.

Software Toolbox has reduced risk for System Integrators since 1996. We reduce risks associated with the use of third party or add-on software to major HMI/SCADA/MES packages, and the risks of writing custom software to meet a specific need. The software products we provide involve applications in reporting, data collection, device integration, remote data connectivity, logging, visualization, OEE, SCADA, cloud services, and more are used in all industrial verticals and are trusted by users in over 110 countries.

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Software Toolbox Inc.

Our risk reduction formula is equal parts of providing a variety of off-the-shelf software products, combined with the knowledge of how they work with major supplier’s software products or together on their own, to solve real manufacturing operations challenges, and back it with support that, well, you just have to experience the difference.

Email: jweber@softwaretoolbox.com

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System Integrator Corporate Close-Ups

Hargrove Controls & Automation

THE RIGHT PEOPLE IN THE RIGHT PLACE AT THE RIGHT TIME.™

failure predictions, reliability and availability

As a leading system integrator, Hargrove Controls & Automation is one of few multi-discipline automation groups in the country capable of providing turnkey solutions for plant automation, safety systems, industrial internet of things (IIoT), and industrial digitalization. Here at Hargrove, we have built a solid reputation by providing clients with solutions to the challenges they face. Whether in a new or existing facility, our Team focuses our efforts in deploying new technology, control strategy development and implementation, as well as migrating legacy systems to new platforms. Our Team specializes in DCS/PLC/SIS system integration, and our digitalization expertise extends into AI-enabled advanced process control, equipment failure predictions, reliability and availability analyses, multi-variate analysis, and advanced dashboarding and workflow, implementing the vision of Industry 4.0

Hargrove Controls & Automation implements control systems for pulp and paper, petroleum and chemical, life sciences, power generation, and other industrial facilities. The Team consists of process control engineers and specialists, certified process safety engineers, cybersecurity professionals, networking specialists, programmers, instrumentation designers, and panel builders. We function as “One Team”, fostering a culture of safety that cultivates quality throughout the project lifecycle while leveraging industry best practices. Based on your needs, our Team will operate as an independent system integrator or with the full complement of our global EPC firm, Hargrove Engineers & Constructors and our asset life cycle management company, Tormod. Hargrove and Tormod provide complete solutions including engineering, automation, total asset life cycle management, fullservice EPC, and technical services. Tormod specializes in transitioning engineered facilities into operating assets with both shortterm commissioning assistance and long-term operations contracts. The success of our Team of companies stems from building the most talented engineers and construction professionals while maintaining long-term client relationships.

For more information about Hargrove Controls & Automation, please visit https://hargrove-epc.com/automation.

Capabilities

• One-team Automation

• Control Systems Platforms

• Panel Fabrication

• Software Development

Corporate Headquarters

Mobile, Alabama / 251.476.0605

KEY EXECUTIVE

Karen Griffin, Vice President

Hargrove Controls & Automation

• Process Safety

• IT/OT and Cybersecurity

• Plant Historian

• Custom Training Development

Other Office Locations:

• Angleton, TX

• Atlanta, GA

• Baton Rouge, LA

• Beaumont, TX

• Birmingham, AL

• Concord, CA

• Decatur, AL

• Greenville, SC

• Factory Acceptance Testing

• Digital Transformation

• Houston, TX

• Lake Charles, LA

• Memphis, TN

• Monterrey, MX

• Pasadena, TX

• Pascagoula, MS

• Philadelphia, PA

• Savannah, GA

CONTACT INFORMATION:

Nicolas Hausman, Marketing Leader nhausman@hargrove-epc.com p: 251.375.5924 | c: 618.954.9071

System Integrator Corporate Close-Ups

PROJECT & OPERATIONAL STRATEGY. THOUGHT LEADERSHIP & VENDOR INDEPENDENCE

A worldwide leader in automation and information solutions, RoviSys is committed to making businesses more secure and more profitable. For over 30 years, customers have relied on RoviSys for information management solutions, manufacturing automation, control systems integration, building automation, warehouse automation enterprise and industrial networks, MES, and Industrial AI. We deliver solutions that drive productivity, improve product quality, increase asset utilization and integrate technology. Our reputation of quality and continuity is built on technical expertise and dedicated customer service.

Engineering Offices

• Asia-Pacific: Singapore, Taiwan, Indonesia, Malaysia

• Europe: The Netherlands

Capabilities

• Process Automation

• Building Automation

• Discrete Manufacturing Automation

• Warehouse Automation

• Control Systems Integration

• North America: Ohio, North Carolina, Texas, Michigan, Massachusetts, California, Georgia

• Manufacturing Execution Systems (MES)

• Industrial Network Solutions

• Building Management Systems

• Electrical Power Management Systems

• Analytics for Business & Process

• Electrical & Instrumentation Design

• Enterprise Networking

• Software Development

• Consulting

Companies with large and small-scale operations, across nearly every industry partner with RoviSys for services and solutions ranging from problem identification to project completion. When asked why RoviSys is preferred over the competition, the prevailing answer is experience and vendor independence, paired with a unique ability to manage, deliver and support projects. Our flexibility to do what’s right for customers is the key to satisfaction and success.

Primary Industries

• Chemicals

• Life Sciences

• Consumer Goods

• Data Centers

• Mining & Metals

• Oil & Gas

• Paper & Wood

• District Energy & Microgrids

• Semiconductor

• Automotive

• Water/Wastewater

• Glass

The RoviSys Company Dick CiammaichellaBusiness Development Director dick.ciammaichella@rovisys.com 330.995.8600 • rovisys.com

Adaptive Resources

Falon Simmons, Vice President McKinney, TX

Telephone: (469) 270-5503

fsimmons@adaptiveresources.com www.adaptiveresources.com

Primary Industries

• Food & Beverage

• Power

• Consumer Products

• Automotive

• Medical Devices

Other Office Locations

• Calgary, AB

• McKinney, TX

• Guadalajara, Mexico

WE APPLY DOMAIN KNOWLEDGE AND FUNDAMENTAL SCIENCE TO MINIMIZE VARIANCE AND MAXIMIZE RESULT

Adaptive provides a range of solutions and a unique combination of technology and expertise for managing processes. More than systems integrators or software engineers, we provide the consulting and design services to minimize process variability and yield better quality and less power usage or waste.

Since 1992, Adaptive Resources has applied scientific principle to advance process control. From their Quick Study suite of advanced control technology solutions to process consulting, systems integration, Adaptive has always focused on delivering the information and tools needed to manage the most complex manufacturing processes.

Core competencies

• Quick Study APC Advanced Process Controls software suite (MPC)

• Systems Integration

• Machine Vision and Robotics

• UL 508 Industrial Control Panel Fabrication

Strategic Partnerships

• ABB Robotics

• B&R

• Cognex Partner SI

• Datalogic

• Denso Robotics

• Festo

• Keyence

• Microscan SI

• Rockwell Automation Recognized SI

• Siemens Solution Provider

• Universal Robots

ANDRITZ

+43 316 6902 0 automation@andritz.com andritz.com

Primary Industries

• Pulp and Paper

• Mining & Mineral Processing

• Hydro

• Seperation

• Process Equipment Automation & Optimization

• ANDRITZ operates over 280 sites worldwide. Please obtain contact details of our global locations online.

• Headquartered in Graz, Austria, founded in 1852.

ANDRITZ SUPPLIES AUTOMATION AND DIGITALIZATION CONTROL SYSTEMS FOR EVERY STAGE OF YOUR PLANT PROCESS.

ANDRITZ is a globally leading supplier of plants, equipment, and services for hydropower stations, pulp and paper, metalworking and steel industries, mining, and solid/liquid separation in the municipal and industrial sectors, as well as for animal feed and biomass pelleting.

ANDRITZ Pulp & Paper: Continuous research and development activities focus on supporting customers to achieve sustainable production with higher capacities and higher energy efficiency while minimizing the consumption of energy, chemicals, and water.

ANDRITZ Hydro: A global supplier of electromechanical systems and services (“from water-to-wire“) for hydropower plants and one of the leaders in the world market for hydraulic power generation. More than 180 years of accumulated experience in turbine design. Over 31,900 turbines (more than 471,000 MW) installed globally. Over 125 years of experience in electrical equipment.

ANDRITZ Automation & Digitalization is a leading supplier of machine and plant control systems with 110 company locations worldwide. ANDRITZ provides automation services and tools for a wide range of process industries, including pulp and paper, mining, lime and cement, power, and oil and gas. ANDRITZ automation defines electrical system capacity and utility requirements, establishes an equipment numbering system, works with process engineers to accurately assign control devices to process equipment, and produces effective E&I construction and maintenance packages. As a technology leader with extensive and long-term experience in supplying industrial measurement, control, and optimization solutions for various industries, ANDRITZ is combining its process and equipment expertise with the latest advancements in the digital era. The result of this powerful combination is Metris: a portfolio of ANDRITZ Digital Solutions.

System Integrator Corporate Close-Ups

Diane M. Haig

Chief Knowledge Officer

Orion Township, MI 48359

Telephone: 248-409-2051

www.appliedmfg.com

Core Competencies

• Warehousing / Logistics

• Packaging

• Material Handling

• Front- and End-of-Line Solutions

• Turnkey Controls

• Robot Programming

• Automation Consulting

Arlene Weichert, VP Sales & Marketing Neptune, NJ, (732) 922-6611 aweichert@automated-control.com www.automated-control.com

Primary Industries:

• Chemical

• Food & Beverage

• Life Sciences, Medical Device

• Oil & Gas

Other Office Locations

• Rockville, MD

• Hudson, MA

• Wesley Chapel, FL

Applied Manufacturing Technologies

“AMT

KNOWS THEIR STUFF AND ARE A GOOD COMPANY TO WORK WITH”

That’s a direct quote from a customer we designed and built a custom automation system for. At the risk of sounding boastful, that testimonial is pretty typical for us. We specialize in providing complete automated turnkey systems from concept and design through field start-up and production support.

We bring diverse capabilities and realworld manufacturing experience to provide our customers with innovative automation solutions aimed at improving costs, simplifying operations and avoiding costly mistakes.

If you are brand new to automation, rest assured that AMT will work with you every step of the way to ensure the best possible project outcomes. Introducing automation takes more than just installing robots and conveyors. We have been helping our customers automate processes for more than thirty years; we know the pitfalls and understand how to steer clear of them.

Already have some processes automated and want to add more? We can do that too. We understand how to work with facility constraints and how to integrate with existing systems.

Put our team’s automation expertise to work for you. We will evaluate your needs and requirements to propose the most appropriate solution, ranging from incremental process improvements to a fully-automated solution.

“Without their superb level of support and dedication, our project would not be where it is today.”

Automated Control Concepts

DELIVERING VALUE FOR DIGITAL TRANSFORMATION

Automated Control Concepts (ACC) is North America’s premier provider of highquality control and information products, services, and solutions to life sciences and manufacturing companies.

Founded in 1983, ACC is a leading ‘Industry 4.0’ solutions provider helping businesses leverage technology and data to optimize manufacturing operational efficiency, quality and compliance. Specializing in OT networking and infrastructure, cybersecurity, process automation and manufacturing intelligence, ACC provides solutions from initial requirements definition and system design through the implementation and commissioning of plant-wide automation and manufacturing execution systems. ACC delivers solutions to manufacturers in a variety of industries, including life sciences, infrastructure and food & beverage. ACC also offers two proprietary software products focused on life sciences – Lab Owl® bioreactor control system and TruTraq® environmental condition monitoring. The OP/Station® division of ACC offers industrial computer workstations designed for NEMA 12/4/4X and hazardous duty environments.

Full Profile at www.cfemedia.com/systemintegrator/automatedcontrolconcepts

System Integrator Corporate Close-Ups

Cassia Networks

Sanja Pesich, Sr. Marketing Communications Manager

97 E. Brokaw Road, Suite 130, San Jose, CA 95112

(408) 444-9150

sanja.pesich@cassianetworks.us www.cassianetworks.com

Primary Industries:

• Industrial IoT

• Digital Health

• Personnel and Asset Tracking

• Smart Campus - Education

• Smart Building, Smart City

Other Office Locations:

• San Jose, California, USA

• Beijing, China

ENTERPRISE BLUETOOTH IOT PRODUCTS AND SOLUTIONS –CASSIA NETWORKS GROUNDBREAKING TECHNOLOGIES

Cassia Networks made the 2022 Red Herring Top 100 Global Winners list in recognition to Cassia’s potential! Cassia’s patented technologies redefine and enable Bluetooth for Enterprise IoT by making it more like Wi-Fi, without sacrificing its low-power, low-cost advantages. For enterprise IoT customers, Cassia provides scalable, flexible, and secure Bluetooth IoT products and solutions that can easily connect and manage billions of low power devices, and significantly lower the enterprise IoT customer’s entry barrier and cost. This technology has brought value to an impressive roster of clients in 30 countries on five different continents.

Cassia Bluetooth gateways support long range communication (up to 1km), one-to-many connections (up to 40), roaming capabilities for all connected devices, flexible backhaul (Ethernet/Wi-Fi/Cellular), easy integration with customer application software, and strong edge computing support. Cassia’s IoT

Access Controller software (AC) can be deployed in the cloud or on local servers and supports easy and centralized management, end-to-end security, Bluetooth locationing, and Bluetooth roaming.

With its groundbreaking Bluetooth IoT technologies, products, and solutions, Cassia previously won multiple awards: the Best-of-CES award in 2016, Bluetooth SIG’s Imagine Blue innovation award in 2017, and Medtronic’s global supplier best innovation award in 2021.

ECS Solutions

BATCH AUTOMATION EXPERTS FOCUSED ON YOUR PLANT MANUFACTURING ECOSYSTEM

Evansville, IN www.ecssolutions.com info@ecssolutions.com

Primary Industries

• Chemical

• Beverage & Distilleries

• Food & Bakery

• Life Science

• Metals (812) 479-5170

Other Office Locations

• Atlanta, GA

• Bowling Green, KY

• Lexington, KY

• Louisville, KY

• Knoxville, TN

• Nashville, TN

• Phoenix, AZ

• Raleigh, NC

• Venice, FL

ECS is dedicated to performance improvement and innovation in batch manufacturing. Our vision of steady, sustainable growth with a diverse customer base is the foundation for making ECS a good place to work. ECS is a recognized leader in the delivery of process control systems, having achieved that status by aggressively pursuing solutions that provide the information and controls our customers need to manufacture more products faster and at a lower cost. We understand that rapid developments in technology necessitate new approaches to control systems – approaches that allow people to filter and consume information more quickly so they can make the best decisions and take immediate action to follow those decisions through. Our leadership team is focused on adding value to our customers’ process and ultimately improving their bottom line.

ECS operates under the guiding principles of excellence in all we undertake, measured internally by profitability and externally by satisfying requirements, and trust that we earn by demonstrating integrity and technical prowess, that we extend to those who prove trustworthy, and that we maintain through communication. ECS’ core values are instilled in every employee to consist communicate candidly, build trusting relationships, serve others well by being responsive, lead with the courage to take risks, continuously improve in response to changing markets and technologies, disarm conflict by handling it one on one, seek excellence rather than perfection to meet the objective, and make ECS a better place to work by being trusting and trustworthy.

Full Profile at www.cfemedia.com/systemintegrator/ecssolutions

System

www.etechgroup.com

Telephone: 1-513-935-0100

Headquarters: 8614 Jacquemin Dr, West Chester Township, OH 45069

Primary Industries

• Life Sciences

• Mission Critical

• Food and Bev/CPG

• Manufacturing

• Material Handling

Other office locations

• Alabama

• California

• Indiana

• Michigan

• New Hampshire

• New York

• North Carolina

• Ohio

• South Carolina

• Texas

• Mexico and Canada

Kimberly Pelkey

Wilson, NC

Telephone: (252) 237-3399

kpelkey@ias-nc.com www.ias-nc.com

Primary Industries

• Pharmaceuticals

• Tire & Rubber

• Wire and Cable

• Chemical and Film

• Food and Beverage

Other Office Locations

• Garner, NC

• Cedar Point, NC

E Tech Group

WE PROVIDE HIGH-QUALITY AUTOMATION, CONTROL, AND ENGINEERING SERVICES FOR INDUSTRIAL CLIENTS.

E Tech Group is one of the largest engineering and system integration firms in the United States. With locations throughout the United States, Canada and Mexico and with over 380 engineers, we provide automation, control, and information solutions to the Life Sciences, Mission Critical, Metals, Parcel, Consumer Products and Food & Beverage industries. Four respected system integration brands – E Technologies, Glenmount Global Solutions, Superior Controls and Banks Integration - came together to deliver consistent solutions across the United States, pairing deep industry knowledge and experience with innovative and comprehensive engineering solutions.

Our scale allows us to help our clients develop and implement standardized solutions at any of their facilities regardless of physical location. We have the capability to bring together large teams of diverse professionals to provide turnkey projects, as well as offer professional project and program management, procurement, panel builds, site and subcontractor supervision, installation and commissioning services, and more.

From full turnkey design/build projects, to staff augmentation, small upgrade projects, E Tech Group has the right people, expertise, and industry experience to deliver for you.

Industrial Automated Systems

Your plant comes with its own set of unique challenges and goals. Our automation specialists collaborate with your team to produce solutions tailored specifically to your needs. Whether we’re designing a new system or updating your existing systems, IAS will devise a plan to both enhance productivity and reduce costs.

Manufacturing Automation

Partners / Affiliates

System Integrator Corporate

The JDI Group, Inc.

Mike King, Principal Director of Operations

Toledo, OH (Maumee)

Telephone: (419) 725-7161 mking@thejdigroup.com www.thejdigroup.com

Primary Industries

• Food & Beverage

• Chemicals

• Manufacturing

• Fats & Oils

• Agricultural / Fertilizer

Lindsey Kielmeyer, Business Development Director

Telephone: (614) 761-5600

Fax: (614) 761-5601 saleseng@martincsi.com www.martincsi.com

Primary Industries

• Automotive

• Chemical

• Factory Automation

• Food and Beverage

• Life Sciences

TRUSTED AUTOMATION SOLUTIONS PARTNER SOLVING PROBLEMS >>> DRIVING PROGRESS

Functional Safety Eng (TÜV Rheinland) | ISA/IEC 61511 SFS (SIS)

• Automation & Instrumentation

• PLC / DCS / HMI Programming

• Panel Design & Fabrication

• Safety Systems Design

• Commissioning & S/U Support

• Operator & Maintenance Training

• PFD and P&ID Development

• Instrument Specification

• Arc Flash & Power Distribution

• SCADA / MES

• Network Design

• IT / Cybersecurity

TRUSTED INTEGRATION FOR BUSY MANUFACTURERS

You’re busy. You need to be able to hand your controls automation projects off to someone you can trust to do it right. We invest in getting to know your processes and challenges; your goals and expectations. Elevating the systems integration experience, together. You can expect us to provide the highest quality industrial control services:

• Automation controls

• PLC programming

• Control panel design

• Controls upgrades

• Motion controls

• SCADA/HMI development

• Data collection/IIoT

• Machine safety services

• Machine vision systems

• Robotics

System Integrator Corporate Close-Ups

David Blaida, CEO/President Maumee, OH

djblaida@matrixti.com 419-897-7200 www.matrixti.com

Primary Industries

• Food & Beverage

• Wine & Spirits

• Consumer Products

• Life Sciences

• Chemical

• Metals

• Oil & Gas

• Feed/Grains/Oilseed

• Aggregates & Mining

Other Office Locations

• Atlanta, GA

• Cincinnati, OH

• Denver, CO

• Indianapolis, IN

• Kansas City, KS

• Maumee, OH

• Minneapolis, MN

MAVERICK Technologies Columbia, IL

888-917-9109

mavtechglobal.com

Primary Industries

• Chemical

• Oil & Gas

• Food & Beverage

• Pulp & Paper

• Life Sciences

Other Office Locations

• Albuquerque, NM

• Atlanta, GA

• Baton Rouge, LA

• Benton Harbor, MI

• Birmingham, AL

• Charlotte, NC

• Chicago, IL

• Dallas, TX

• Exton, PA

• Houston, TX

•

•

•

Matrix Technologies

“GO BEYOND AUTOMATION – YOUR SINGLE SOURCE SOLUTION”

Matrix Technologies is the only company you need to call for your next capital investment.

We are a truly single-source solution for all of your engineering, automation and information needs.

87% of our projects are repeat engagements with satisfied clients.

• Consulting

– Pre-Engineering for capital project scope and cost development

– 3D Facility and Process Laser scanning for baseline/ ground penetrating radar

–Automation Master Planning

–Digital transformation

–Network Investigation and Design

–Cyber Security

–MFG. Transformation Assessement

• Detailed Engineering

–Facility Design

–Process Conceptual and Detailed Design

–Network Design

–Mechanical and Piping Design

–Virtualized Server Systems

–Electrical Distribution and Control

–Process Automation

–Manufacturing Intelligence/MES Systems

–Energy Tracking and Reduction

–Performance Monitoring and Improvement

–Standards Development & Governance

• Application Expertise

–Industrial OT/I4.0

– Virtual Server Environments/Distributed Technology

–Raw Material Handling

–Batch System Design

–Batch System Automation

– Filling and Packaging Systems

–Track and Trace Systems

–Manufacturing Intelligence/Continuous Improvement

–Manufacturing Operations Management, MES & Systems

• Engineer, Procure and Construct Services (EPC)

–Upfront Engineering Scope and Construction Planning

–Full Engineering Design through Stage Gate Project Delivery

–Industrial Controls/Automation, Startup/Commissioning

–Coordination with Preferred local Contractors and Vendors

–Project and Construction Management – PMI Practices

–Greenfield and Brownfield Capital Investments

– Industrial Buildings, Process and Packaging Line Expansions

MAVERICK Technologies

INDUSTRIAL AUTOMATION & SYSTEMS INTEGRATOR

MAVERICK Technologies, A Rockwell Automation Company, is a systems integrator in North America, and a global leader in Industrial Automation, Enterprise Integration and Strategic Manufacturing Solutions. With more than 400 professionals on staff at 21 locations, we work with clients across a wide range of manufacturing and process industries.

We’ve completed more than 15,000 projects in 46 countries across six continents, and we’re ready to leverage all that experience in delivering a solution for you. From process controls to strategic-level consulting, we’ll work with you to identify suboptimal operations and improve your safety, efficiency and overall profitability.

www.cfemedia.com/systemintegrator/mavericktechnologies

System Integrator Corporate Close-Ups

Pacific Blue Engineering

Pacific Blue Engineering

TRUSTED CONTROL SYSTEM INTEGRATOR PARTNER FOR MANUFACTURING, TRANSPORTATION, AND RIDE ENGINEERING

Primary Industries

• Food and Beverage

• Entertainment

• Transportation

• Life Sciences

• Manufacturing

Other Office Locations

• Long Beach, CA

• Modesto, CA

• Irvine, CA

• Phoenix, AZ

Pacific Blue Engineering is a premier automation integrator that leverages the latest industrial automation technology to deliver unique solutions for our customers’ challenges in a broad range of industries. Our true end-to-end services provide a single vision for our customers’ projects, from planning and design, to programming, building, installation, commissioning, testing, and validation.

We have served 200+ customers, in 4 countries, for 8 industries, and executed more than 1,050 jobs.

Long Beach, CA info@pacificblueengineering.com www.pacificblueengineering.com (657) 201-8603 Full Profile at www.cfemedia.com/systemintegrator/pacificblueengineering

Patti Engineering

Telephone: (800) 852-0994 sales@pattieng.com www.pattiengineering.com

Primary Industries

• Automotive

• Consumer packaged goods

• Distribution & sortation

• Food & Beverage

• Glass

• Heavy Industry

• Pharmaceutical

• Water & wastewater

Our culture is the attitude we bring to work every morning. We work hard, do what’s right, pay attention to detail, and focus on achieving measurable results. We take pride in crossing our t’s and dotting our i’s so our customers don’t have to.

Services and Solutions

• Machine Safety Controls

• Turn-Key Control System Integration

• SCADA

• Networks & Infrastructure

• Legacy Controls Migration

• UL508A Panel Build & Design

• AutoCAD Electrical Drafting

Patti Engineering

Founded in 1991, Patti Engineering, Inc. offers high-caliber engineering and software development services to integrate automation technology in world-class industrial facilities so that your business runs faster, smarter, and more reliably. Patti Engineering is a seventime CSIA Certified Integrator and partners with the world’s leading industrial automation suppliers, including: Siemens, FANUC, Beckhoff, Mitsubishi, and Ignition.

We use our knowledge of these technologies to design solutions to meet our clients’ needs. Project management is our strong suit with functional specs a standard, a project manager on all projects, and regular communication throughout the process. Patti Engineering is known for becoming trusted advisors to our clients, helping them improve the efficiency, safety, and quality in their facilities.

We have a wide range of Manufacturing Automation and Intelligence expertise:

• IIoT/Industry 4.0

• PLCs & CNCs

• Robotics

• Process Simulation

• Virtual Commissioning

• MES/SCADA

• Motion Control

• RFID/RTLS

• Vision Systems

Certifications & Associations

• TUV SUD and TUV Rheinland Functional Safety Engineers

• UL 508A Panel Shop

• CSIA member

• ISNetworld / Avetta

Experienced, degreed engineers complete all of our engineering, and Licensed Professional Engineers are on staff. Patti Engineering has experience not only in floor level automations, but also with Industry 4.0 Technologies.

Outstanding customer satisfaction and project success earned Patti Engineering placement in Control Engineering magazine’s System Integrator Hall of Fame.

System Integrator Corporate Close-Ups

Premeir Automation

Premier Automation Sales

Sales@premierautomation.com

Monroeville, PA

Telephone: 412-373-3700 www.premierautomation.com

Primary Industries

• Metals

• Aerospace

• Entertainment

• Glass & Plastics

• Oil & Gas

Other Office Locations

• Alpharetta, GA

FROM CONCEPT TO COMPLETION –WHEREVER YOU NEED A PARTNER, WE CAN HELP!

Premier Automation is an engineered solutions company that specializes in providing automation, drive and electrical control solutions and services to industrial markets. Premier Automation offers cost effective, industry specific technology solutions to help our customers increase their industrial productivity, efficiency and overall systems performance. We take the time to understand your unique process and requirements, and then work closely with you to develop the best control solution for your need. What sets Premier Automation apart is the wide range of in-house services that we offer which provides reliable, complete, fully integrated customer solutions. From concept to completion, our engineering, production & field service staff are unmatched in industrial automation experience and ability. Premier Automation serves as a true electrical control partner to companies that are in need of innovative solutions, strategies & support to help them compete successfully in today’s highly competitive global environment.

Full Profile at www.cfemedia.com/systemintegrator/premeirautomation

Quantum Design Control Systems

Quantum Design Inc. Caledonia, IL 61011 815-885-1300 qdisales@quantumdi.com www.quantumdi.com

Primary Industries

• Agriculture

• Aerospace, aircraft

• Food & Beverage

• Pharmaceutical

• Material handling, logistics, warehousing

A CONTROLS SYSTEM INTEGRATOR PROVIDING TURNKEY SOLUTIONS FROM DESIGN THROUGH COMMISSIONING

Since 1986, Quantum Design Control Systems has been a leading systems integrator serving the automation controls market by designing, building and deploying control systems throughout the world. We are committed to providing our customers with cost effective solutions using the most appropriate technology and products with proven reliability in a wide range of demanding environments and applications. Our controls engineering knowledge and panel production excellence is unique and provides customers a complete, turnkey solution.

Quantum Design’s team of engineers come from many different industry backgrounds and deliver broad ranging expertise in the following key areas:

• electrical engineering/design

• control system and panel design

• motion control a/programming

• CNC design/implementation

• Legacy system upgrades

• Logic programming and HMI development

• plant data integration, reporting and visualization

• and more….

Quantum Design provides full support throughout the project including installation support, start up, field service and training.

In addition, Quantum Design is a self-certifying, UL508A panel assembly shop and proficient at developing CE compliant controls systems. We employ the best technicians and assemblers and each system is inspected by our dedicated Quality Assurance team. Our ISO 9001:2015 Quality Management System ensures adherence to requirements and empowers us to continually improve. Quantum Design has been featured on Control Engineering’s System Integrator Giants list since 2019.

System Integrator Corporate Close-Ups

Danny Smith

Head of Business Development

danny.smith@gotoSAGE.com www.gotoSAGE.com

Primary Industries

• Manufacturing

• Mining/Resources

• Utilities/Water/Energy

• Transport / Smart Cities

• Defence

Office Locations:

• Australia - South Australia, Victoria, New South Wales, Western Australia, Queensland, Northern Territory and Tasmania

• India – Pune, Mumbai

ACCELERATE YOUR DIGITAL JOURNEY WITH SAGE

SAGE Group is a global company with a team of more than 600 people over two continents, committed to creating a Smarter Future, Better World.

As an integrated industrial digitalization services provider, SAGE has specialist brands and software solutions that combine to support clients to lead into the future on their digital transformation journey, with the perfect balance of technology, process, and capability. SAGE clients are world leaders and innovators looking for a smarter way of doing things and together, we are on a mission to make the lives of everybody smarter, safer, and more sustainable.

Specialist Brands

SAGE Automation Industrial automation design, delivery, and support Nukon Digital operations consultancy and delivery for smart decision making using whole-of-business insights

Embedded Expertise Matching high-calibre technical expertise with agile clients Skills Lab Creating a workforce that thinks smarter with industry 4.0 capability

Software Solutions

TilliT Manufacturing’s no-code digital platform

Addinsight Unlocking powerful transport insights using real-time movement data

TESCO

Shain Thomas, CEO Sacramento, CA (916) 395-8800 sales@tescocontrols.com https://tescocontrols.com

Primary Industries

• Water, Wastewater

• Renewable Energy

• Electrical Utilities

• Transportation Office Locations:

• Phoenix, AZ

• Brea, CA*

• Salinas, CA

• Temecula, CA

• Orlando, FL

• Atlanta, GA

• Maui, HI

• Baton Rouge, LA

• Carson City, NV

• Irving, TX*

CONTROL SYSTEM SOLUTIONS FOR A SMARTER UTILITY

TESCO is a national system integrator focused on delivering well-designed control system solutions that automate processes for water/wastewater treatment, distribution, and storage. We partner with clients to deliver end-to-end systems, from initial concepts, assessment and design, to programming, manufacturing, installation, and commissioning. TESCO’s ability to offer a complete suite of professional services, manufacturing, and installation capabilities helps clients to manage schedule, quality, performance risk, and final outcomes.

Client services: system assessments, system design, engineering, programming, SCADA-HMI development, project management, commissioning, 24/7/365 technical support, training, and long-term service options. We are CSIAcertified and certified in all major control system software platforms.

TESCO designs, fabricates, and customizes control panels, MCCs, PLCs, VFDs, switchgear and instrumentation at our 130,000 sq. ft. Sacramento facility, offering options for custom dimensions, cabinet colors, configurations, and materials. We are a UL-certified OEM for all major industry equipment vendors. We also have UL panel shops in Brea California* and Irving Texas*.

TESCO’s project execution methodologies range from design-bid-build to design-build and collaborative delivery. With over 50,000 projects completed since 1972, client satisfaction is our primary objective. At TESCO you are not “just a project;” instead, each project is part of our long-term client commitment to consistently meet and exceed your expectations.

System Integrator Corporate Close-Ups

Velta Technology

Global Headquarters

119 South Main Street

St. Charles, MO 63301

www.veltatech.com

asktheexperts@veltatech.com

314-463-3600

Primary Industries

• Manufacturing

• Chemicals, Petrochemicals

• Utilities

• Food, Beverage

• Process Industries

• Pharmaceuticals

DIGITAL SAFETY AND SECURITY FOR INDUSTRIAL ENVIRONMENTS

Velta Technology specializes in Digital Safety and Cybersecurity for the industrial space. We understand industrial assets and infrastructure to bridge the gap between Industrial IoT and OT/IT convergence. We are knowledgeable of the differences between industrial and IT infrastructures and the toolsets required to secure them.

Who are we?

The Velta Technology team is comprised of multi-disciplinary industrial manufacturing and critical infrastructure experts. Recognized as Claroty Partner of the Year in North America, and a Cisco IoT Advantage Partner, we have relationships and partner with the world’s leading solution providers in the industrial space.

We offer clients:

Michelle Hammer

Business Development Manager

4409 E Baseline Rd #127 Phoenix, AZ 85042 615-208-4979

vertech.com

Primary Industries:

• Food & Beverage

• Solar Energy

• Water & Wastewater

• Manufacturing

• Irvine, CA

• Phoenix, AZ

• Nashville, TN

• Austin, TX

• Over 100 years of combined OT/ IT Industrial, Enterprise & C-suite experience

• Laser-focused on the industrial and manufacturing space

• Platform agnostic solutions with world-class partners across technologies & environments

• Proprietary Velta Technology Standards, Platforms & Methodologies

• Specialized Digital Safety / Cybersecurity Training program

• Expert resources and support as an extension to your internal terms

We help companies and organizations integrate digital safety solutions, expertise and tools, with existing technologies. We bridge the gap in expertise and understanding from industrial assets on the plant floor across to the enterprise. With over 1,000 points of entry, they only need one.

Velta Technology - Get Safer Sooner

Vertech

A "RIVER GUIDE" FOR DIGITAL INDUSTRIAL SOLUTIONS

At Vertech, we believe there's a human way to do industrial automation.

Yes, we design bulletproof MES, SCADA, OT, and Controls solutions that are a joy to use. But we're also your long-term ally. No more endless change orders. No more paying good money for a half-solution. We're here to reduce your tech-related stress, not add to it. And who knows? You might even enjoy the process.

If you need a long-term guide to help you traverse the ever-changing rapids of industrial technology, we’ve got a paddle. Jump on in.

System Integrator Corporate Close-Ups

Paul Sondreaal, Director of Business Development

Eden Prairie, MN Telephone: (952) 933-3222 paul.sondreaal@wmeng.com www.wmeng.com

Primary Industries

• Water / Wastewater

• High tech

• Oil & Gas

• Pharmacuetical or Life Sciences

• Food and Beverage

Other Office Locations

• Over 30 offices Nationally

Wunderlich-Malec

WUNDERLICH-MALEC: THE GO-TO TEAM FOR YOUR ENGINEERING, SYSTEM INTEGRATION, AND FABRICATION NEEDS.

Clients in a wide variety of industries rely on Wunderlich-Malec for advanced engineering solutions. The demands on today’s leaders require complex solutions to help manage their business. Cost reduction, regulatory requirements, security, and rapidly changing market dynamics require fully integrated operations. Since 1981 Wunderlich-Malec has excelled at creating and deploying the total solutions they need to meet these business objectives. We believe the key to our success is our depth of talent, proven methodologies and exceptional flexibility. Our people are passionate about solving your unique engineering challenges, and with the support of industry experts behind them, they can successfully execute projects of any size while meeting the demands of your industry.

Wunderlich-Malec is a 100% employee-owned company (ESOP). With offices throughout the US and over 500 professionals on our staff, we are one of the largest and most well established engineering companies in the United States. Our success is fueled by our strong and long-lasting customer relationships guided by our 3 part culture – Our Pledge, Process and People. We’re confident that our qualified staff has the knowledge, experience and talent to create and deliver the solutions you need for your integration needs.

aeSolutions

ADVANCED AUTOMATION PROJECT DELIVERY

aeSolutions, from the earliest inception phases to final turnover, provides the project delivery and technical expertise to guide you to success on your project and business objectives. Through a proven project delivery model, aeSolutions integrates diverse hardware, software, and services from multiple vendors and client stakeholders into a unified, integrated system

• Process Control

• Batch Control

• Complex Migrations & Upgrades

• Burner Management

• Combustion Control

• Industrial Fire & Gas

• Industrial Networks

• Material Handling

Stephen Powell

Client Success Manager

aeSolutions Greenville, SC (864) 404-3026 www.aeSolutions.com

Primary Industries

• Petrochemical & Oil & Gas

• Pharmaceutical

• Specialty & Agricultural Chemical

Our full range of services will lead you through the controls integration process to deliver a fully integrated, cohesive control system in a wellexecuted project.

Automation Plus

AUTOMATION PLUS PROVIDES INNOVATIVE, COST EFFECTIVE, TURNKEY MANUFACTURING SOLUTIONS

Our talented and dedicated engineers at Automation Plus utilize a wealth of industrial control system expertise to deliver plant centric, business driven, automation solutions for our clients.

We work directly with your management, operations, and maintenance staff to ensure that your goals are realized while designing and implementing control systems that are operator-friendly, maintainable, and cost-effective.

Dennis Romak dromak@plusgroups.com 513-742-7590

Primary Industries

• Chemical

• Pharmaceutical

• Food & Beverage

Our engineers and specialist possess substantial operating floor and system startup experience in manufacturing, process, and packaging systems. In addition, we have a team of industry-seasoned professionals to address Cybersecurity concerns and ensure your business is protected. Our team utilizes proven best practices for project execution and design, leading to a nimble, best in class solution, customized for each client.

System Integrator Corporate Close-Ups

Avanceon

YOUR PARTNER IN DIGITAL TRANSFORMATION

With the changes in the world over the past few years, at the front of every manufacturer's mind is automation and data use. As you focus your digital transformation journey, Avanceon is ready to partner with you to leverage nearly 40 years of innovating experience in manufacturing OT and IT systems and programs.

Our expertise covers:

• Project Requirements, Consulting and ROI definition

Susan Schlegel

Vice President of Sales

610.458.8700 Ext: 300 sschlegel@avanceon.com www.avanceon.com

Primary Industries

• Food & Beverage / CPG

• Water / Wastewater

• Industrial

• Solution Development (New Controls Systems, Upgrades, SCADA, MES, ML / Analytics)

• After Project Hypercare, 24X7 Support and Training

Check out the difference Avanceon can make from both a technological and systematic perspective as you navigate these challenging times.

Gray Solutions

TRUSTED LEADER IN PROCESS INNOVATION

Daniel Lyrek VP, Sales & Marketing daniel.lyrek@graysolutions.com 612-716-3187

Primary Industries

• Food & Beverage

• Consumer Based Goods/ Products

• Life Sciences

Gray Solutions, a global systems integrator, delivers outcome-focused, comprehensive solutions across the Food & Beverage, CPG, and Life Science industries. As a trusted partner of some of the world’s most recognized brands, our innovative approach to optimizing complex integrated processes enables rapid, transformative results for projects of all sizes. Our expertise ranges from highly automated production facilities and advanced industrial networks, to enterprise applications and highly secure solutions. Our team of skilled professionals, informed by the ever-evolving capabilities of technology, utilize expertise to deliver results, pairing your priorities and objectives to meet your strategic initiatives.

Electronic Drives & Controls SYSTEMS THAT WORK

With a 50-year track record and thousands of satisfied customers, EDC is a recognized leader in the Design, Upgrade, and Service Support of Drive and PLC Systems.

If you appreciate the value of quality, please give us a call. We want to do business with you.

• CSIA Certified

• Siemens Solution Partner

• Rockwell Authorized System Integrator

Chuck Dillard, Vice President 973-428-0500

chuck.dillard@electronicdrives.com service@electronicdrives.com www.ElectronicDrives.com

Primary Industries

• Wire and Cable

• Coating/Converting/ Laminating

• Metals Slitting and Strip Processing

GTH

MODERNIZE YOUR OPERATION WITH SEAMLESS CONTROL AND AUTOMATION SOLUTIONS.

George T. Hall (GTH) is a full-service solutions provider. With a legacy of 90 years in business, we are experts in the areas of:

• PLC Modernization

• SCADA/ OEE Solutions

• Combustion Technology

• Process Control Upgrades

Corporate Headquarters Anaheim, CA 714-939-7100

https://www.georgethall.com/si/ integrationsupport@georgethall.com

GTH brings experience and intuition to automation challenges and creates sustainable, reliable control solutions. We’ll work within the framework of your existing technology to modernize operations or design new systems when you’re looking to expand. We have longstanding relationships with automation hardware and software suppliers to provide the best possible solutions.

Primary Industries

• Water/Wastewater

• Mining, Minerals, & Metals

• Pharmaceutical

System Integrator Corporate Close-Ups

Huffman Engineering Inc.

HUFFMAN ENGINEERING: MAKING IDEAS WORK FOR 35 YEARS

Named 2022 System Integrator of the Year, Huffman Engineering (HEI) has served municipalities and industrial customers since 1987. HEI provides innovative engineering solutions, start to finish, on an array of complex problems. Huffman Engineering can design, program and build robust and reliable automation systems to meet the expectations of the CDPHE, FDA, USDA and EPA. Our documentation is detailed and consistent, allowing our customers to be prepared to validate any regulatory requirements. Our engineers and technicians provide best in class water/electrical power solutions to major metropolitan cities and small rural communities. With pharmaceutical and food and beverage proficiency extending to every step of the bioreacting, batch mixing and weight, processing and visioning/packaging progressions, our resident expertise is second to none.

Howard Huffman, President

Phone:

402.464.6823

info@huffmaneng.com www.huffmaneng.com

Primary Industries

• Pharmaceuticals

• Water & Wastewater

• Food & Beverage

• Electrical Utilities

McEnery Automation

OPTIMIZING ASSETS AND PRODUCTIVITY

McEnery Automation combines extensive process control knowledge with OT and IT expertise to deliver scalable, cost-effective solutions that optimize assets and productivity. We help clients with their digital transformation journey by integrating the plant floor with information systems.

McEnery Automation’s engineers are experts in Process, Control and Information systems. Now in our 30th year, our success is built upon hiring and developing engineers that are skilled in each of these areas.

Steve Holland

Info@McEneryAutomation.com

St. Louis, MO 636-717-1400 www.McEneryAutomation.com

Primary Industries:

• Food & Beverage

• Consumer Products

• Lubricants & Chemicals

This unique approach allows our team to not only understand the process data, but also how to put it to use by business systems and analytical tools to optimize assets and productivity.

Interstates, Inc.

TRANSFORM YOUR OPERATIONS AND MEET PRODUCTION PROMISES

Interstates, Inc. is a total systems integrator with the ability to automate all of a plant's equipment, collect and provide data reporting from operations, and design the interface with business systems to give an owner real-time tracking and control. With decades of experience and proven expertise, we partner with our clients to find industrial solutions from operational technology to analytics to automation.

Interstates, Inc. 1400 7th Avenue NE

Sioux Center, IA 51250 712-722-1662

bdev@interstates.com www.interstates.com

Primary Industries:

• Consumer Packaged Goods

• Food & Beverage

• Value-Added Agriculture

• Warehouse & Distribution

Since 1953, Interstates has thrived on solving the most complex challenges to ensure your facilities stay up and running with no unplanned downtime. As a system integrator, we have the capacity and the know-how to deliver solutions on schedule, on budget, and on target with your needs.

SCIO AUTOMATION

AUTOMATING LOGISTICS AND PRODUCTION PROCESSES

SCIO Automation Group is an international automation platform that passionately believes in its mission to support companies on their journey towards Industry 4.0. As a system integrator, SCIO automates production and logistics processes. As an innovator, SCIO develops value-added and customized automation products for the Autonomous Mobile Robots, Software and Cleanroom sectors, as well as for Food Intralogistics and Industrial Labeling. The SCIO platform currently comprises ten company brands, totaling more than 1000 employees at 30 locations in eight countries worldwide, all of whom play a part in implementing the Smart Factory concept for global players and hidden champions in a wide range of industries.

SCIO Automation GmbH Dürkheimer Straße 130

D-67227 Frankenthal www.scio-automation.com info@scio-automation.com +49 (0)6233-6000-650

Primary Industries

• Automotive (OEMs, Suppliers)

• Material handling, logistics, warehousing

• Electronics, semiconductor

System Integrator Corporate Close-Ups

Polytron

PROVIDING 40 YEARS OF INNOVATIVE FULL SYSTEM MANUFACTURING SOLUTIONS

With full-system engineering expertise, our advanced knowledge and project management best practices, ensure the highest degree of project success at a lower risk. Polytron supports your business goals from start-to-finish including controls, process, mechanical, packaging, and digital transformation solutions. Our strong leadership and project managers are your trusted partners to help you design, implement, and validate your vision for a sustainable future.

We deliver:

• Advanced Smart Manufacturing solutions

Rande Allen, Vice President

855-794-7659

marketing@polytron.com www.polytron.com Primary

• Long-time expertise in process and packaging

• Proven results-driven project management

• Industry-recognized Industrial Networks and Security expertise

• Professional PEs, PMPs, and TÜV safety engineers

• C ertified expertise in major industry technologies for unique solutions

WES-TECH

GIVING YOU A COMPETITIVE ADVANTAGE IN FACTORY AUTOMATION SINCE 1976.

Build success and improve operational excellence with the forward-thinking Wes-Tech engineering team.

• I nnovative Automation Solutions

• Engineering Expertise

• Creative Implementation

• O ver 600 yrs of Collective Automation Experience

• ISO 9001:2015 Certification

• UL 508A Certification

• S killed Electro-mechanical System Design

Jay Lee Buffalo Grove, IL 864-386-2652

jlee@wes-tech.com www.wes-tech.com

Primary Industries

• Automotive

• Manufacturing

• Consumer Products

• Integration & Factory Automation Equipment

www.wago.com/us/ macsec-switches

MACsec SWITCHES

Industrial Managed with Integrated Encryption Functions

There is no reason to be concerned with plant floor data security. WAGO’s industrial MACsec managed switches provides data encryption per IEEE802.1AE MAC Security via the bottom two ports. These compact devices can be placed in existing control cabinets to help increase cyber security.

Your advantages:

• Simple configuration

• Easy to install in existing systems

• Point to point data encryption

input #12 at www.controleng.com/information

• Encryption of any Ethernet protocol Protect data from