Global System Integrator Report December 2025

C ONTENTS

5 | CSIA continues its mission to help SIs create optimum businesses, Certification update

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Global System Integrator Report

O NLINE C ONTENTS

Read additional system integration articles

online.

https://www.controleng.com/supplement/global-system-integrator-report-digital-supplement

• Automating end-of-line genset testing for maximum throughput (A) — ACS

• Five lines in one year: Scaling high-volume glass automation with precision — DRM

• How to harness reliable OT networks to power digital transformation — E Tech Group

• Verify and remain compliant: Why label verification is critical for food manufacturers — Grantek

• Digital transformation in print manufacturing: from manual processes to smart production — Industrial Automation Systems

• How to integrate EI&C for project delivery — Revere

• How to bolster uptime with time-series data storage (B) — Iconics

• GSIR 2025 expert questions and answers — System integrator roundtable

• Find system integrators online: www.controleng.com/Global-SI-Database

• Find more system integration topics: www.controleng.com/system-integration

• Get the System Integration newsletter. Sign up here: www.controleng.com/subscribe

System integrators are powering industrial transformation

Gary Cohen

FROM AI TO ANALYTICS, today’s SIs are helping manufacturers bridge the gap between operations, IT and strategy.

Welcome to the 2025 Control Engineering and Plant Engineering Global System Integrator Report. Each year, we take the pulse of the system integrator (SI) community — the engineers, project managers and business leaders connecting technology to production across the globe. This year’s findings reveal an industry in motion, shaped by increasing system complexity, smarter automation and evolving expectations from end users seeking speed, flexibility and measurable outcomes.

System integrators remain the essential link between innovation and execution.

They are the ones transforming buzzwords like “AI,” “digital twin” and “smart manufacturing” into working systems that boost productivity and resilience. Yet as technology advances, so do challenges like finding specialized talent, navigating cybersecurity demands and delivering seamless integration across operational technology (OT), information technology (IT) and cloud environments, all while keeping projects on time and within budget.

A clear trend that stands out in 2025 is the rise of specialization. Integrators are setting themselves apart through deep vertical expertise, domain knowledge and value-added services that extend well beyond commissioning. From process optimization to analytics and predictive maintenance, SIs are moving upstream, helping clients shape digital strategies and

“SIs are… helping clients shape digital strategies and long-term transformation goals that define modern industrial performance.

“

long-term transformation goals that define modern industrial performance.

Whether you’re an integrator, manufacturer or automation supplier, this year’s report offers an inside look at how the industry is adapting — and where it’s headed next. GSIR

Gary Cohen, senior editor, WTWH Media, gcohen@wtwhmedia.com.

(B)

(A)

CSIA empowers system integrators to thrive in a changing landscape

With updated certification programs, expanded learning resources, and a renewed focus on digital transformation, CSIA continues to help system integrators build stronger, more adaptable businesses worldwide.

The Global System Integrator Report provides a yearly update on the cornerstone of a successful industrial automation project: the system integrator. Over the two decades, the rapid increase in technological advancements has transformed this role from one that automated the plant to one that conceptualizes data transit, acquisition and analysis for customers. SIs are at the forefront of the evergreen discussions of operational technology (OT) and information technology (IT) convergence, working to determine how and when it helps customers to use innovative technologies such as AI, digital twins, software-defined automation and more.

Evolving system integrator role

Yet as technology has become more dynamic, the wider geopolitical world has also become more chaotic. After having worked through the backlogs from the COVID-19 pandemic, today’s SIs and their customers are adapting to market uncertainty related to tariffs and input costs. Despite the economic and political shifts with which they are coping, system integrators need to ensure that their own businesses are successful, profitable and adaptable. Over the past 30 years, the Control System Integrators Association (CSIA) has helped system integrators do exactly this. Most notably through the CSIA Best Practices Manual, CSIA has helped its members build strong businesses and advance the impact system integrators have in industry. Following CSIA best practices and demonstrating this through CSIA Certification provide industry with the assurance that projects can be completed quickly, efficiently and professionally.

Modern certification, more learning

Because of this, CSIA has been working to ensure that its certification practice is keeping pace with trends in manufacturing. You can read more about how CSIA is reshaping its certification practice to adapt to the increase in mergers and acquisitions.

This allows the organization to support SIs who wish to properly reflect the depth and extent of a certification across an entire organization. CSIA has recently launched the CSIA Learning Hub to provide its members with access to affordable, high-quality and relevant professional development content as an enhancement to their existing onboarding processes and employee development programs. Additional education for industry can be found by listening to CSIA's members talk about their businesses and projects on the Talking Industrial Automation podcast. These changes would have been impossible without the leadership of Jose Rivera, the previous CEO of CSIA who served from 2015 to 2025. Under his guidance, CSIA saw significant modernization, increased resilience and a strong financial position. After a decade, Rivera announced in December 2024 that he would be stepping down. The board of directors of CSIA and I are grateful for his unwavering commitment and efforts to ensure a seamless transition of leadership.

Looking ahead: Next generation support

As we look forward to the next decade at CSIA, I will be working with the members to build on the core benefits they receive from the organization: enhancing the educational resources, peer-approved best practices and unparalleled networking opportunities that they can rely on. Digital transformation will continue to provide SIs with opportunities to offer greater value, requiring changes to the sales approach, client engagement, business models and more. When SIs tackle these changes, CSIA will be there to support them. How can we help you? GSIR

Adrienne Meyer is CEO of the Control System Integrators Association (CSIA), a not-for-profit, global trade association that seeks to advance the industry of control system integration. CSIA is a WTWH Media content partner. Edited by Gary Cohen, senior editor, Control Engineering, gcohen@wtwhmedia.com.

Learningu

Insights

Control system integrators use their engineering, technical and business skills to help manufacturers and others automate their industrial equipment and systems.

The mission of CSIA is to help system integrators build successful businesses and advance the impact system integrators have in industry. CSIA has more than 400 member companies in 35 countries.

CSIA hosts the Industrial Automation Exchange to connect manufacturers and others with the system integrators and industry suppliers who best meet their automation needs.

ONLINE www.controlsys.org, and follow the association on LinkedIn, Facebook and YouTube.

Adrienne Meyer, CEO, Control System Integrators Association (CSIA)

Control System Integrators Association (CSIA)

Updating CSIA Certification for large, integrated, multisite organizations

Through teamwork among E Tech, Exotek and CSIA leadership, the system integration industry gains a new model for enterprise-wide certification.

Healthy driver s, i ncluding the increasing demand from manufacturers for automation solutions, have generated overall good growth for system integrators over the past few years. This growth has been accomplished organically (e.g., by expanding geographically or into targeted industry verticals) or through mergers and acquisitions (M&A). When companies grow, they often reach a point where they must reorganize to operate and grow successfully. In addition, when growth is achieved through M&A, managers need to determine if they want to drive toward integration (full or partial) or not at all.

Learningu

Objectives

• Understand how system integrator growth through mergers and acquisitions creates new challenges and opportunities for organizational alignment and certification.

• Learn how E Tech Group, in collaboration with CSIA and Exotek, developed and implemented an enterpriselevel audit model for multilocation certification.

• Recognize how adapting certification frameworks can strengthen business practices, unify company culture and support sustainable growth.

CONSIDER THIS

• How can our organization leverage the CSIA Certification process to align and integrate our business practices across multiple locations and acquired companies?

Growth brings new organizational and certification challenges

Regardless of how they are growing, it has been valuable for system integrators of all sizes to ensure and demonstrate that they are aligned with business best practices. It has been a core offer of the Control System Integrators Association (CSIA) to define those best practices and provide a certification to them. Since its inception, this CSIA Member Certification process has examined and granted certification to specific, single operating locations. While this approach has worked for companies with one or a small number of operating locations, the size, number of locations and underlying organizational structure that stems from the acquisition of several companies, each with multiple locations, creates increasing pressure to consider different methods of certification.

Different paths to growth and integration

One approach is for the various companies to hold high levels of independence, including retaining previous company names and cultures, but to achieve synergies through shared services (often HR and finance) or increased purchasing volume. From the perspective of the CSIA Certification program,

these cases are relatively simple. If desired, those independent companies apply individually for the certification of their companies. If they pass the audit, these companies will hold the CSIA Certification for the next three years, but this certification will not extend to any parent or sibling entities of the company.

An opposite approach is for the company to complete a full merger of all its entities into a single entity with many locations, including moving to a single company name. This new company could be organized along various P&L centers covering different geographies or industry verticals while leveraging shared service centers. From the perspective of the CSIA Certification, this is a more complex situation and has caused the association to create a variation to its certification process.

Mergers are challenging not only because they involve most aspects of the business, but also because they touch the human element: the company culture, history and identity. The drive toward a common internal process framework, as defined by the CSIA Best Practices, can be a foundational catalyst for that integration. While it may take more than just an audit and certification, setting an audit target date and gaining input from an independent third-party auditor through the CSIA audit can spur the entire organization to make it happen.

Enterprise level audit pilot with e tech group

E Tech Group has undergone dramatic growth in the past few years because of both organic growth and aggressive M&A funded by private equity. The histogram below explains the evolution.

While not all companies follow the same path, E Tech Group was clear from the start that they would pursue the integration of their companies under a single brand. While this is easy to articulate, it takes significant effort to accomplish. Superior Controls, the first system integration company

to receive CSIA Certification in 2000, joined E Tech Group in 2019. The benefits that Superior Controls derived from pursuing and maintaining the CSIA Certification incentivized the rest of E Tech Group to deploy the CSIA Best Practices, the base for the CSIA Certification. It is worth mentioning that the original E-Technologies received its first CSIA Certification in 2013 and retained it until 2019, at which point they let the certification lapse to lead the integration process. They intended to pursue the certification for the larger company that would emerge post integration.

How did this audit take place?

Having progressed significantly toward their integration goals, E Tech Group initiated re-certification discussions in 2024 with CSIA and Exotek, a CSIA Certified Auditor. E Tech Group previously utilized Exotek audit services for their legacy companies, and they wanted to explore a possible companywide certification. This would represent something fundamentally different and more comprehensive than what the current certification and audit process offered. The standard approach provides an audit for the “Head Office,” followed by audits of all the “Branch Offices.” This would have been challenging for E Tech with more than 25 locations nationwide. However, because E Tech Group operates as a single entity with a single brand and a clearly defined corporate headquarters, with business units separated by geography and core competencies, there was an opportunity to create an audit plan specific to E Tech Group that could ensure representativeness and properly reflect the depth and extent of their certification across the entire organization — not just a portion of it.

Exotek brought its audit expertise and a strong familiarity with several of the legacy companies that are now part of E Tech, dating back to the first CSIA certification of Superior Controls. Collaborating closely with E Tech, Exotek designed a tailored audit plan that offered valuable insights into the company’s enterprise structure. This plan was subsequently reviewed and approved by CSIA as part of the certification process.

The corporate headquarters was audited on topics like general management, human resources management and financial management. The business units were audited on specific parts of human resources management, such as “training and professional development,” as well as relevant

“CSIA has expanded continuously since its founding in 1993.“

—CSIA

impactful sections, such as project management, system development lifecycle, etc. All business units were audited on common topics (e.g., project management). To properly represent the level of accomplishment required with this new audit format, the company’s final audit results contained the consolidated scoring from all audited areas of the organization, reflecting the lowest score obtained with respect to each audit criterion.

Certification as a unifying framework

Most SIs pursue CSIA Certification for the value it brings in strengthening their business practices. For E Tech Group, the certification process has served as a unifying framework, helping align its portfolio of companies with CSIA’s Best Practices. CSIA extends its congratulations to E Tech Group, and especially to Gary Powell, PE, senior vice president of operations, for championing this initiative. Powell played a pivotal role in advocating for the development of this certification option and led internal efforts to prepare for the audit.

Special thanks also go to Brian Mullen, P.Eng. and senior management consultant, of Exotek, who designed, developed and executed the pilot audit plan in close collaboration with E Tech. His leadership was instrumental in shaping the process that made this achievement possible.

Finally, CSIA thanks its former CEO, Jose Rivera, for guiding the creation of the framework that allowed the CSIA Certification to adapt and meet the evolving needs of CSIA members. In addition, he was the primary author of this article, and we thank him for his contributions in providing this information. GSIR

Control System Integrators Association (CSIA), www.controlsys.org, is a WTWH Media content partner. Edited by Gary Cohen, senior editor, Control Engineering, gcohen@wtwhmedia.com.

Insightsu

CSIA Certification insights

uSystem integrators’ rapid growth through M&A has created a need for CSIA to evolve its certification process to fit multilocation enterprises.

u E Tech Group collaborated with CSIA and Exotek to pilot an enterprise-level audit model that certifies an entire organization under one framework.

uThe partnership between E Tech, Exotek and CSIA leadership modernized the certification program to better serve today’s large, integrated system integrators.

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Awarding excellence System Integrator of the Year, 2026

Omnicon (under $20 million), Vertech ($20 million to $40 million), and Thermo Systems (over $40 million) received recognition from Control Engineering and Plant Engineering.

The three winners of the System Integrator of the Year award for 2026, from Control Engineering and Plant Engineering, WTWH Media, are:

• Thermo Systems (over $40 million in system integration revenue)

• Vertech ($20 million to $40 million in system integration revenue)

• Omnicon (under $20 million in system integration revenue)

Control system integrators regularly update and expand automation and control system integration capabilities and talent to help clients remain competitive, relevant and useful. In this accelerating world of technology developments and market demands, congratulations to the applicants who answered questions and assembled supporting documents to become System Integrator of the Year finalists. Thank you.

System Integrator of the Year 2026, judges, process

Meet the judges for the 2026 System Integrator of the Year award, who volunteer time for the challenging and rewarding selection process. They rank the finalists in 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, BRL Consulting, https://brlconsulting.com

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

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

• Shari Worthington, Ph.D., president, Telesian Technology Inc., www.telesian.com

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

• Stephanie Neil, vice president, editorial director, engineering, automation & control, WTWH Media, www.wtwhmedia.com/control-automation-network

Anticipating future system integration excellence

Award winners are announced in the Global System Integrator Report, a supplement to the November/December 2025 issues of Control Engineering and Plant Engineering. The award is dated for the next year in recognition of anticipated system integration excellence to come. These articles highlight the 2026 System Integrator of the Year companies in three system integration revenue categories.

Edited by Mark T. Hoske, editor-in-chief, Control Engineering, www.controleng.com, WTWH Media, mhoske@wtwhmedia. com Amanda Pelliccione, marketing research manager, WTWH Media, administers the System Integrator of the Year program. Learn more; link to past winners: www.controleng.com/SIY.

2026 System Integrator of the Year

Chocolate, oil and gas automation

Omnicon is the winner in the under $20 million in system integration revenue category.

Omnicon is the 2026 System Integrator of the Year award winner in the under $20 million in system integration revenue category. The company discussed automation and control system integration achievements, projects, engineering development and metrics, among other topics.

What are you particularly proud of?

We are proud that our application reflects Omnicon’s journey from a regional system integrator to a trusted global partner in smart manufacturing, digital transformation and industrial automation. This recognition is especially meaningful because it validates our commitment to delivering high-quality, internationally recognized solutions — combining formal methods and disciplined processes with a deep understanding of our customers’ needs, guiding them through their digital transformation journeys with a human and adaptable service culture.

Our story demonstrates a mature and globally scalable business model. With offices in the United States, Colombia, Mexico and Spain, and projects delivered in more than 67 countries, Omnicon provides world-class engineering supported by Control System Integrator Association (CSIA) certification, ISO standards and four consecutive recognitions among Deloitte’s Best Managed Companies.

This success is driven by a passionate team committed to continuous learning and technical excellence, and by a culture that turns innovation collaboration and curiosity into measurable results.

The customer’s goal was to improve performance and yield, harmonize processes, enhance traceability and strengthen quality control across facilities. Omnicon deployed a scalable and standardized operational framework that established consistent data structures for plant-floor to MES and enterprise resource planning (ERP) integration. By aligning workflows and digitalizing production data, we enabled real-time performance monitoring, improved product consistency and reduced process variability. This initiative enhanced operational efficiency and laid the groundwork for the client’s global analytics and sustainability programs.

Another project that we are proud of is a regional manufacturing convergence initiative for a leading company in the consumer health sector, with major production sites in Colombia and Brazil. The customer was facing persistent difficulties integrating multiple legacy systems, managing siloed operations and aligning geographically dispersed teams under one manufacturing execution strategy. Omnicon conducted a comprehensive multi-phase assessment involving documentation review, on-site analysis, connectivity and data-flow mapping and cost modeling. This approach enabled us to identify integration gaps, risks of system obsolescence and opportunities for automation and data standardization. As a result, we delivered a convergence roadmap that served as the foundation for the customer’s digital transformation strategy in Latin America, restoring confidence in the project’s feasibility and accelerating decision-making for the global MES rollout.

Online controleng.com

https://omniconint.com

For more, see this article online and the Omnicon entry in the Global System Integrator Database.

https://gspplatform.cfemedia.com/si/integratorProfile/6671a9c052769277fb0e69fc

Describe several system integration projects

We are most proud of the projects that have pushed us to combine deep process knowledge, strong engineering discipline and advanced digital capabilities to solve our clients’ most complex challenges. Each project reflects our mission to transform manufacturing operations into connected, data-driven and sustainable environments.

One of our most remarkable recent projects was a multi-country manufacturing execution system (MES) program across 80 production lines in 6 countries for the world’s leading chocolate manufacturer.

We supported a major oil and gas company, by leading the modernization of automation systems across more than 10 refining and production facilities nationwide. The main objective was to migrate obsolete control systems to modern platforms, ensuring higher availability, safety and operational continuity. Our multidisciplinary team designed and implemented a phased migration strategy that minimized plant downtime while maintaining compliance with strict process safety standards. We standardized engineering methodologies and documentation practices across all sites, ensuring future maintainability and scalability. This effort improved system reliability and interoperability, enabling data integration into enterprise-level dashboards for better asset management and predictive maintenance.

Each of these projects embodies the principles that define Omnicon’s success: technical excellence,

Awarding excellence

deep process understanding and collaboration with clients to deliver measurable outcomes. By combining automation, data analytics and digital transformation strategies, we have helped organizations in food and beverage, consumer packaged goods (CPG), chemical, energy and pharmaceutical industries achieve greater productivity, transparency and resilience in manufacturing operations.

Have customer expectations changed?

We are focusing on:

• Designing modular and scalable architectures that evolve with business needs.

• Integrating analytics and data governance from the start to ensure decision-making value.

• Strengthening cybersecurity frameworks to sustain trust and reliability.

• And above all, co-creating with clients, so technology becomes a strategic enabler, not just a tool.

The discussion has shifted from selecting the right technologies to understanding how technolo

How do you help younger engineers?

Every project is a learning platform for our customers and our people. Guiding younger engineers is fundamental to our identity as a company that has grown by sharing knowledge and nurturing talent. We believe that expertise is built through real project experience, structured mentorship and continuous education.

Please share a long-term company goal

Our long-term vision is to continue growing as one while enjoying the journey — expanding globally and nurturing a culture of excellence, innovation and collaboration. We are committed to strengthening our footprint throughout the Americas and Europe, with particular emphasis on the United States and Mexico, becoming a trusted

global partner in smart manufacturing and industrial digitalization and automation. Our goal is to grow in scale and evolve in impact — empowering our people, deepening our technical expertise and delivering meaningful value to our clients through sustainable, high-quality solutions.

We are committed and passionate about becoming the leading engineering and technology partner for organizations seeking transformation and integrated, scalable solutions that deliver tangible business value. We focus on innovation, operational excellence and trusted relationships, while building strong teams and processes to lead change in the industrial technology ecosystem.

Key metrics

Key metrics include:

• With more than three decades of experience, Omnicon has completed over 3,000 projects across 67 countries, supported by a multidisciplinary team of +100 professionals. Our delivery footprint spans North America, Europe and Latin America, reflecting our ability to serve clients through hybrid execution models.

• Across industries such as food and beverage, chemicals and energy, we have consistently achieved high project reliability and customer satisfaction — the result of our emphasis on process quality, technical rigor and continuous improvement which reinforces our role as a complete partner in digital transformation.

These indicators highlight more than just scale; they reflect a company built on adaptability, consistency and long-term partnerships. Sustained growth, combined with employee development and client retention, remains the foundation of our success as we continue to expand our impact and redefine what excellence in industrial integration means. GSIR

Daniel Gomez is chief operating officer of Omnicon.

“By aligning workflows and digitalizing production data, we enabled real-time performance monitoring, improved product consistency and reduced process variability.“

OMNICON TEAM PICTURE: (from left to right) Jhon Calvo, engineering director; Daniel Gomez, COO; Gustavo Ramirez, sales director; Jenny Giraldo, CFO and Eduardo Acosta, CEO. Courtesy: Omnicon

2026 System Integrator of the Year

Device data unification, optimization

In the $20 million to $40 million in system integration revenue category, Vertech is the winner.

Vertech is the 2025 System Integrator of the Year award winner in the $20 million to $40 million in system integration revenue category. The company discussed automation and control system integration achievements, projects, engineering development and metrics, among other topics.

What are you proud of?

Vertech is particularly proud of the story behind our growth — because it’s not just about the numbers, it’s about what they represent. In the past two years, Vertech has nearly doubled in revenue, but what makes that meaningful is how it happened.

That drive comes from a team that genuinely cares about doing things right — technically, strategically and relationally. Our clients trust us with more work year after year because they know we’ll deliver systems that impact operations. And at the same time, our marketing and sales teams have been intentional about expanding into new verticals, like data centers, in a way that aligns with our strengths and values.

Yes, the revenue growth is exciting, but it’s really a reflection of exceptional people — from recruiters to sales reps and engineers to project managers — who’ve built lasting relationships and executed with excellence. It’s proof that when you focus on delivering genuine value, growth takes care of itself.

Describe a few system integration projects

www.vertech.com

For more, see this article online and the Vertech entry in the Global System Integrator Database. https://gspplatform. cfemedia.com/si/integratorProfile/5565cb7be4b0008dfc008d7f Online controleng.com

Right now, we’re especially proud of the work we’re doing in the data center space. Many of our current projects are under non-disclosure agreements (NDAs), so I can’t share specifics. What I can say is that we’re developing architectures to address some of the industry’s toughest challenges, particularly around power-hungry, graphics processing unit (GPU)-intensive, liquid-cooled systems.

These architectures bring together advanced MQTT unified name space (UNS)-like data unification from devices for integration across the information technology/operational technology (IT/OT) landscape. By integrating cooling and power systems [building management systems (BMS) and electric

power monitoring systems (EPMS)], we’re helping operators optimize performance, improve energy efficiency and reduce overall power consumption. We’ve also designed these systems with scalability in mind using a library-based architecture that makes new deployments faster and more adaptable.

For us, the success comes down to impact: enabling our clients to meet massive data demands more efficiently, sustainably and intelligently. It’s cutting-edge work that aligns perfectly with where Vertech is heading — using innovation to elevate how critical infrastructure operates worldwide.

Our top five target industries are: Solar and renewable energy, data centers, water and wastewater, food and beverage, and manufacturing.

Has the supply chain affected projects?

As system integrators, we’ve always lived at the intersection of hardware suppliers and end customers. When the global supply chain tightened, that balancing act became even more delicate. Our approach was to lean into relationships and transparency rather than retreat from them. We made it a priority to frequently communicate, keeping our suppliers looped in on project forecasts and our customers informed about shifting lead times or pricing updates. That openness built the trust we needed to keep projects on track, even when circumstances were unpredictable.

Over time, those lessons have fundamentally changed the way we serve our customers. We’ve adapted our planning processes to be more proactive, our project designs to be more flexible and our communication to be more collaborative. When parts or hardware become unavailable, we don’t just wait it out — we partner with clients to evaluate alternative solutions, adjust specifications, or re-sequence project phases to keep momentum going. We’ve built systems that provide real-time visibility into supply status, pricing and inventory, giving our team and our customers the information they need to make quick, confident decisions.

The supply chain has tested us, but it also has strengthened us. It’s made us faster to adapt, better partners to our clients and more intentional about how we plan, communicate and deliver. In many ways, those challenges have made us a more resilient and customer-focused organization.

“Control Freak University is a four-week, on-site training program designed to turn smart graduates into confident control systems engineers.“

How do you help younger engineers?

We believe investing in the next generation of engineers is key to sustaining excellence and innovation. That’s why we launched Control Freak University this year — a four-week, on-site training program designed to turn smart graduates into confident control systems engineers. Because we’re a remote-first company, this immersive experience gives new hires hands-on exposure to real-world tools and workflows from day one. Depending on the role of new hires, they dive deep into fundamentals like panel layouts, industrial networks, PLCs, human-machine interface (HMI), supervisory control and data acquisition (SCADA), and the Scrum framework, all while learning from experienced mentors. The program culminates in a team-based capstone project presented to a panel of senior engineers, simulating a true client delivery experience. By the time they return to their home offices, they’re equipped with the technical skills and collaborative mindset needed to contribute meaningfully to projects right away.

Please share a long-term goal

“Our long-term goal at Vertech is to become a truly full-service OT partner equipped with the capability set and capacity to meet every operational technology need our clients face,” explained Titus Crabb, Vertech president. “That means offering strategic consulting to align OT with business goals, delivering world-class consulting, engineering, development, and integration services, and providing reliable ongoing support. To get there, we’re investing in deep industry expertise, a broad range of technical skillsets, and a geographic presence that allows us to serve our clients where they are.”

Doing all that will help with the big, hairy, audacious goal (BHAG) is to reach $500 million in revenue with a team of around 1500 people by 2035. But it’s not just about getting bigger. It’s about amplifying our mission to elevate human well-being by enabling the efficient, reliable delivery of quality goods and services worldwide. That growth will empower us to take on more complex projects, invest more in our people, and innovate in ways that make a real difference. It’s a vision that unites our team around building opportunity and lasting impact for our clients, partners, and the communities they serve.

Awarding excellence

Provide a few metrics

Key metrics include:

23% revenue growth: Fueled by tremendous momentum in our energy and data center verticals, this growth reflects the exciting trajectory we’re on toward our BHAG of $500 million in revenue by 2035 and the expanding impact of Vertech’s solutions across industries.

31% team growth: Driven by domestic expansion and the opening of our first international office in India, this growth demonstrates our investment in people — ensuring we have the talent, capacity and global reach to meet growing customer needs while maintaining exceptional service.

“We’ve focused on preserving our culture and ensuring that rapid growth doesn’t dilute what makes Vertech special,” said Bob Morris, Vertech vice president.

49% year over year earnings growth: “Our earnings growth is outpacing revenue, a clear sign that we’re becoming more efficient and disciplined as an organization. This efficiency not only strengthens our bottom line, it also empowers us to reinvest in innovation, people and infrastructure, fueling the next phase of our growth journey,” said Bob Morris, Vertech vice president. GSIR

Wendy Brodeur is marketing operations lead, Vertech.

FIGURE 2: Vertech president, Titus Crabb (left), managing director India, Sudeep Somwanshi (center), and vice president, Bob Morris (right) cut the ribbon at the Vertech India office grand opening in October 2024.

FIGURE 1: Vertech director of digital plant, Ryan Crownover, delivers a presentation on Momentum Method. Images courtesy: Vertech

2026 System Integrator of the Year

Mission-critical power, data center

Thermo Systems wins in the over $40 million in system integration revenue category, aims to drive customer success through reliability.

Thermo Systems is the 2026 System Integrator of the Year award winner in the over $40 million in system integration revenue category. Thermo Systems, a $200+million revenue company, discussed automation and control system integration achievements, projects, engineering development and metrics, among other topics.

What are you particularly proud of?

It’s a great honor to have been selected as the 2026 recipient of the System Integrator of the Year award. This recognition reflects the dedication and excellence of our entire team at Thermo Systems. We are particularly proud to highlight how Thermo Systems continuously strengthens safety, quality and project delivery through formalized initiatives such as our Project Management Office (PMO), Learning and Development, Quality Management System and comprehensive safety programs. These efforts are reinforced by ongoing training, industry certifications and a culture of accountability, demonstrating our team’s commitment to excellence. By benchmarking our processes against industry-best practices and prioritizing customer feedback, we’ve built a model for operational excellence that directly contributes to customer satisfaction and long-term success.

Describe several system integration projects

systems, maintaining 100% uptime during startup, upgrades and maintenance. The solution has since become a standard practice across similar facilities, demonstrating our ability to deliver operational continuity and risk mitigation.

Another success was recovering and completing a stalled automation project for a confidential data center client. By focusing on customer success, restructuring the integration strategy, re-mediating legacy configurations and deploying a robust automation architecture, we restored client confidence and operational continuity — delivering results where others had failed.

Key technologies applied include advanced automation architectures, modular system design, real-time monitoring and rigorous safety protocols. Quantifiable benefits included zero downtime, accelerated project delivery and enhanced safety compliance.

Industries we target most often are mission critical facilities (data centers), life sciences and pharmaceuticals as well as energy and power.

What project methodologies do you use?

www.thermosystems.com

For more, see this article online and Thermo Systems entry in the Global System Integrator Database.

https://gspplatform.cfemedia.com/si/integrator Proile/5399d137e4b025bf87df47da

One of the projects we’re most proud of is our work for a confidential client in the mission critical sector, where we solved a persistent automation challenge: ensuring uninterrupted temporary power during system startup, transitions and maintenance. Our team engineered a proprietary solution modular, scalable and plugand-play — tailored to specific voltage, load and safety requirements. This innovation enabled rapid deployment across diverse

At Thermo Systems, we consistently execute projects using structured methodologies and philosophies such as standardized project management (via our PMO), robust quality management systems and comprehensive safety programs. These frameworks emphasize documented workflows, cross-functional collaboration and continuous improvement. Our approach is evolving to integrate advanced technologies like generative AI, which we formalize through dedicated policies to ensure responsible innovation. We benchmark our procedures against industry best practices, including regular Control System Integrator Association (CSIA, www.controlsys.org) audits, to refine our processes and maintain excellence. This evolution is driven by the need to enhance efficiency, scalability and risk management in a rapidly changing industry, ultimately ensuring we deliver safe, high-quality solutions and outstanding customer satisfaction.

How have customer expectations for system integration projects changed?

Customer expectations for projects have evolved significantly; there is increased demand for greater transparency, faster delivery, higher safety standards and measurable outcomes. Clients expect integrators to be proactive in communication, adaptable to change and capable of solving complex challenges that may arise unexpectedly.

To address these changes, Thermo Systems has formalized project management, quality and safety methodologies and continuously benchmarks against industry best practices (such as CSIA audits). We invest in ongoing training, cross-functional collaboration and advanced technologies (including responsible AI use) to stay agile and responsive. Our plans include maintaining robust feedback loops with customers, refining our procedures based on lessons learned and scaling governance to support international operations. This ensures we can anticipate and adapt to expected and unforeseen changes, delivering operational excellence and customer satisfaction even in dynamic environments.

How important is developing long-term customer relationships and why?

Developing long-term relationships with customers during projects is extremely important for Thermo Systems. These relationships foster trust, enable deeper collaboration and help us understand clients’ evolving needs. By building lasting partnerships, we can proactively address challenges, adapt solutions, and deliver consistent value over time. Long-term relationships support continuous improvement, as ongoing feedback from customers helps us refine our processes and maintain high standards in safety, quality and project delivery. Ultimately, these relationships are key to achieving operational excellence and sustaining customer satisfaction.

Do you help younger engineers?

To help guide younger engineers in projects, Thermo Systems provides structured mentorship, cross-functional collaboration, and hands-on experience through our Project Management Office (PMO) and Learning and Development (L&D) programs. Junior engineers are paired with experienced mentors, participate in documented workflows and are encouraged to take on increasing responsibility as their skills grow.

Ongoing education includes required training in technical skills, safety (OSHA 10/30), leadership development and compliance standards. We support certifications such as Professional Engineer (PE), Certified Automation Professional (CAP), Project Management Professional (PMP) and various information technology (IT) and cybersecurity credentials. Training is delivered through formal programs, online platforms and regular safety and quality sessions, ensuring our engineers are equipped to meet evolving industry needs and standards.

Awarding excellence

Please provide a few metrics

Key metrics include:

Safety: Thermo Systems’ Safety Spotlight Program received 39 peer nominations year-to-date, recognizing employees who demonstrated proactive safety behaviors on and off the job. By empowering our people to identify and celebrate safe actions, we are fostering a behavior-based safety culture that goes beyond compliance. It is a culture driven by shared accountability, recognition and everyday leadership in the field.

Risk mitigation: Our enterprise PMO risk dashboard tracks 100% of active projects, over 250 annually, providing unified visibility into open, in-progress and mitigated risks. With over 80% of risks now tracked through documented mitigation actions, our system ensures accountability, reduces surprises and drives predictable project outcomes.

Learning and Development program: Thermo Systems’ L&D team developed and published 51 new technical training courses this year, supporting an average of 276 active learners per week and driving over 360 weekly course completions through asynchronous learning. In addition to technical development, we deliver custom virtual and in-person leadership programs that build full-scale capability, from emerging leaders to advanced supervisors, technical experts, commissioning managers and project managers, while strengthening our culture of continuous learning and leadership excellence across the organization. GSIR

Sonali Shah is marketing director, Thermo Systems.

“Quantifiable project benefits included zero downtime, accelerated project delivery and enhanced safety compliance.“

FIGURE 1: Thermo Systems engineers perform PLC panel testing and validation. Images courtesy: Thermo Systems

FIGURE 2: Eric Silk is CEO of Thermo Systems.

Automation’s front line: 2026 System Integrator Giants expand capabilities

Average revenue per firm rises about 30% as integrators broaden skills in data, cybersecurity and robotics.

WTWH Media —publisher of Control Engineering, Plant Engineering and the Global System Integrator Report —is proud to present the 2026 System Integrator Giants ranking. Each June, we open submissions and invite system integrators to voluntarily share self-reported revenue from system integration (SI) activities. The resulting list offers a data-driven snapshot of the firms powering automation projects across industries, while reflecting the market forces that shape yearto-year results.

This year’s list again features 75 companies, matching the total from 2025. However, not all of last year’s System Integrator Giants returned to participate in 2026, and several new firms joined the ranking. The group collectively reported $4.67 billion in system integration revenue, a gain of roughly 18% over the prior year. Average revenue per ranked firm rose about 30%, signaling that growth extended beyond only the largest players. Among companies appearing in both years, roughly three-quarters reported higher SI revenue—a sign of continued demand for automation in manufacturing and process industries as organizations seek throughput, quality and workforce leverage.

When asked about the biggest challenges of the past year, participants highlighted:

• The economy’s impact on the automation integrator market (27%)

• Identifying new prospective clients (13%)

• Staffing: quality of young engineers (13%)

• Rising costs of materials and equipment (11%)

• Rising labor costs (8%)

These responses reinforce what we hear across WTWH’s engineering communities: integrators remain uniquely positioned to blend operational technology domain expertise with modern automation, controls and data practices, yet hiring and upskilling remain persistent hurdles. Many firms continue to broaden capabilities in areas such as cybersecurity, edge and cloud connectivity, data analytics and robotics—often in close collaboration with OEMs and end users to standardize architectures and accelerate deployment.

Not all gains were organic. Several firms reflected acquisition-driven changes, which can materially reset revenue baselines. Others noted corrections from prior reporting inconsistencies as teams refined how they attribute revenue to core integration work versus adjacent services. Beyond firm-level changes, macroeconomics played a role: contributors cited tariffs and pricing pressure, equipment and material cost inflation, and labor cost escalation as factors that shaped project pipelines, quoting and delivery.

We caution readers that year-to-year revenue movement can reflect acquisitions, methodology improvements, or timing effects, not just organic growth or contraction. Our aim with the System Integrator Giants program is to provide credible benchmarking while recognizing the diversity of services SI firms deliver— from greenfield design and commissioning to modernization, migration and lifecycle support.

We invite you to explore the full ranking and accompanying analysis in the Global System Integrator Report and on controleng.com. Congratulations to this year’s System Integrator Giants for their continued leadership in advancing safe, resilient and data-ready manufacturing. GSIR

The data for the System Integrator Giants program is voluntarily provided by participating companies between June and September each year. Companies submit information on total gross revenue and total system integration revenue for their most recently completed fiscal year. Participation varies from year to year. For more details, visit www.controleng.com/giants.

Amanda Pelliccione,

Marketing Research Manager, WTWH Media LLC

Aurora, OH, United States

Bottling, canning, brewing, distilling; building envelope, controlled atmosphere; chemicals, petrochemicals; electronics, semiconductor; food, beverage; glass, stone, clay; household, personal care products; information and communication systems; life sciences, biotechnology; material handling, logistics, warehousing; mining, aggregates, cement; oil & gas refining; paints, coatings; pharmaceuticals; pipelines; plastics; pulp, paper, converting; quality control, test and measurement; transportation equipment; water, wastewater; wood, lumber

Verona, WI, United States

Kansas City, MO, United States

AZ, United States

Warminster Heights, PA, United States

LA, United

Auburn Hills, MI, United States

CA, United States

Machesney Park, IL, United States

Topsfield,

Industrial Automation Workforce Development GIANTS SYSTEM INTEGRATOR In Action

Beth Yarbrough, Recruiter and Tony Valasek, Director of Engineering, EOSYS

EOSYS provides custom industrial automation and digital transformation solutions to major companies across the United States, helping clients quickly ramp up manufacturing efforts. To develop its workforce, EOSYS has invested in its cooperative education program, EOSYS NEXT, which identifies and mentors new engineering talent.

How are you addressing the engineer shortage?

Relying on our network is a core tenant of our recruitment process, and we’ve had terrific success with referrals. The EOSYS NEXT Cooperative Education program emphasizes education-focused efforts like sponsoring community STEM events, facilitating college mock interviews, and speaking at IEEE events and to minority-focused engineering groups. We also listen to feedback and adjust where needed.

How did you change your co-op program?

In an effort to emphasize key benefits and the career trajectory offered with our program, we rebranded to EOSYS NEXT and updated the position title to NEXT Engineer. We emphasize program alumni so our NEXT Engineers clearly see the path to becoming difference-making engineers and future leaders. Students in the program receive industry training, hands-on experience under the guidance of a mentor, and the opportunity to work on real, for-profit projects. We offer competitive pay and housing support. We want every student to gain a solid foundation for a long and successful engineering career.

How are you upskilling existing talent?

The EOSYS mindset is to support and develop our talent at every career stage. This allows us to assess skills and plan resources appropriately so we can staff to project requirements. To serve customers over decades, it’s critical to upskill and bring in new talent. Bringing in young talent to overlap with our existing workforce is key. To meet future demands, we invest in people today.

How do both of these help customers?

EOSYS offers regular internal training and labs so employees can expand their skill sets. The success of this approach is evident in the career span of several principal engineers who have worked with one of our long-term customers, one of the top food manufacturers in the United States. These engineers started as entry-level employees and have grown into world-class experts. Our customer supported this model because engineers at the start of their career benefit from the institutional knowledge of experienced engineers, so our customer never has to worry about losing product familiarity to attrition or retirement; and knows they're always getting the most experienced and skilled engineers possible.

What else would you like to add?

EOSYS is dedicated to making sure our employee-owners feel truly valued, and that they’re empowered and supported to contribute every day to the success of the organization. This approach has proven to be successful with both employees and customers. Find more information at https://eosysgroup.com. GSIR

“Investment in developing our workforce is critical to long-term success for our customers and our employee-owners. It's a key part of our continuous improvement and ownership culture.“

EOSYS delivers industrial control solutions that assist clients with optimizing their manufacturing operations.

As a leading industrial control integrator, EOSYS builds the brains behind manufacturing by designing plant information systems and plant floor control systems that assist clients with optimizing their manufacturing operation to improve overall performance.

EOSYS is the 2025 CSIA Integrator Member of the Year.

https://eosysgroup.com

AUTOMATION &

DATA SOLUTIONS

• Control Systems Integration

• Process Automation

• Industrial Digital Transformation

• Panel Fabrication

• Electrical Control Solutions

• Operational Technology

INDUSTRIES INCLUDE

• Food & Beverage

• Chemical

• Consumer Packaged Goods

• Spirits

• Pulp & Paper

• Metals

• Energy & Utilities

• Automotive

• General Manufacturing

OFFICE LOCATIONS

NORTH AMERICA

• Nashville, TN

• Atlanta, GA

• Cincinnati, OH

• Huntsville, AL

• Minneapolis, MN

Capturing expertise, cutting through the hype: RoviSys on industrial AI in manufacturing GIANTS SYSTEM INTEGRATOR In Action

Industrial artificial intelligence (AI) is moving from concept to application, helping manufacturers make smarter, faster, and safer decisions on the plant floor. But according to Bryan DeBois, Director of Industrial AI at RoviSys, success with AI isn’t about hype or headlines— it’s about solving real problems and preserving valuable expertise.

“Manufacturers often come to us unsure of what AI can actually do,” DeBois says. “Our role as an independent integrator is to cut through the noise and focus on what’s real.”

That clarity is needed now more than ever. Across numerous industries, RoviSys is seeing the impact of the “silver tsunami”—the rapid retirement of experienced operators and engineers. “I can’t tell you how many times we ask, ‘Who knows how to fix that?’ and the answer is, ‘Bill knew, but he retired six months ago.’ AI gives us a way to capture that expertise before it walks out the door.”

To address that challenge, RoviSys develops decision-support systems that help novice operators perform at the level of seasoned veterans. “It’s not about replacing people,” DeBois emphasizes. “It’s about enabling them to perform better and make confident, data-driven decisions.”

Unlike traditional control projects, industrial AI initiatives start with data. “If a customer

doesn’t have usable data or a historian in place, we begin with an AI readiness project,” he says. “From there, exploratory data analysis helps identify where AI can make the biggest impact.”

Applications range from predictive-quality models to autonomous AI systems that mimic expert decision-making through deep reinforcement learning. While life sciences remain cautious due to regulation, industries like glass, steel, and aluminum are leading adopters—where even a 1–2% gain translates to significant competitive advantage.

Return on investment is critical. “Nobody’s waiting three years for payback anymore,” DeBois notes. “We target 12 months or less. Smaller projects may yield hundreds of thousands in savings, and larger efforts can exceed a million annually.”

His advice is straightforward: start small, build momentum, and partner with an independent system integrator who can evaluate technologies objectively. “AI vendors each have their hammer,” he says. “A good integrator helps you find the right tool for the right job— and keeps the focus on delivering real, measurable results.”

GSIR

For more information, visit www.rovisys.com/AI or connect with Bryan DeBois on LinkedIn.

“If a customer doesn’t have usable data or a historian in place, we begin with an AI readiness project. Exploratory data analysis helps identify where AI can make the biggest impact.“

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, Illinois, Virginia, Arizona

ASIA-PACIFIC: Singapore, Taiwan, Indonesia, Malaysia, Japan, Thailand

EUROPE: Nederland, Ireland

Dan Idzikowski, Senior staff engineer-instrumentation and controls, ACS

How a controls system upgrade boosts your plant’s efficiency

Upgrading a plant's controls system can significantly boost efficiency and extend the life of existing equipment.

In manufacturing, research and development, your business outcomes are only as good as your equipment. Running a reliable system with optimized performance and efficiency can provide a critical competitive advantage.

Buying industrial equipment isn’t like buying an smartphone. You don’t upgrade. Most manufacturing systems include expensive equipment designed to last for decades. A controls system upgrade can give this equipment a new lease on life for a fraction of the cost of equipment replacement. Technology moves fast, and control platforms are faster and more powerful. They’re designed to seamlessly integrate into existing plant networks.

Benefits of a controls upgrade

There are myriad ways a controls upgrade can give your plant’s productivity a boost. Here are a few:

Learningu

Objectives

• Identify at least three benefits of upgrading a plant's controls system, such as optimized performance and increased visibility.

• Recognize key indicators that signal the need for a controls system upgrade, including unsupported software/hardware and integrated system upgrades.

• Understand how a controls system upgrade can improve operational efficiency and provide a competitive advantage.

CONSIDER THIS

Are your current control systems creating hidden risks or inefficiencies, such as reliance on unsupported software, outdated hardware or mismatched equipment?

• Optimized performance: Modern control systems can collect, store and analyze tremendous amounts of data. They can provide operators critical information to boost energy efficiency, troubleshoot errors and reduce downtime. The computing power of an upgraded controls system can help you operate your entire plant more efficiently.

• Remote access: New controllers have remote support capabilities so you no longer have to be in front of a machine to troubleshoot it. With fewer people looking over more processes, remote access allows monitoring performance from anywhere in the facility using the plant network or even from outside using a secure web connection. Combined with error alerting, your upgraded controls could automatically alert an on-call operator to a failure in the system, even if it happens off hours. In some cases, the operator could log in to the system and either clear the alert or resolve the issue remotely.

• Increased visibility: A controls system upgrade is an opportunity to integrate disparate equipment and sensors into a common control network. You should be able to view information about systems from any screen in the plant. This whole-network visibility helps operators make better decisions about how to prioritize time.

When the system is no longer supported: Your controls system has software and hardware components. Both will eventually reach the end of their useful life. When software versions are no longer supported by modern operating systems, it’s time to upgrade. Using legacy operating systems or operating unsupported software versions is not only inefficient, but it puts your system at risk for viruses and cybersecurity threats.

When the manufacturer of your controllers stops supporting your legacy hardware, it’s time to plan for a controls system upgrade. If you’re left scouring eBay to find replacement parts, a minor hardware failure could have a ripple effect through your entire facility’s ability to operate. It can be a world of hurt if something goes down and you don’t have a stock of replacement parts. When you can no longer purchase your hardware direct from the distributor, it’s time to think about upgrading your system.

When you’re upgrading integrated systems: When you’re upgrading mechanical systems, it’s best to complete a controls system upgrade at the same time to ensure the controllers can communicate effectively with the new equipment.

Whether upgraded controllers are talking to wornout equipment or legacy controllers are trying to understand more powerful new equipment, at a certain point, the age difference between systems can just be too much. The best thing to do is to upgrade across the board. Software, controlling hardware and mechanics. Just upgrading one system does not mean your process has been upgraded. A controls system upgrade creates an opportunity to bring all the controls systems on your site under one umbrella. Maintaining multiple controls systems creates issues with visibility, maintaining parts inventory, managing software upgrades and maintaining training requirements.

Under the right circumstances, a controls system upgrade can maximize your facility’s efficiency and give you a competitive edge. GSIR

Dan Idzikowski, senior staff engineer-instrumentation and controls, ACS. Edited by Gary Cohen, senior editor, Control Engineering, gcohen@wtwhmedia.com.

discover.aveva.com/ water-si-success

Chase Davis, Eosys

7 ways to mitigate brownfield automation integration risks

Smart automation integration requires even smarter planning. Here are the key considerations to make sure your next facility automation and controls upgrade is a success.

As manufacturers look for ways to become more globally competitive, many are turning to brownfield programmable logic controller (PLC) and distributed control system (DCS) integrations to enhance their existing process controls and automation capabilities. These upgrades offer long-term benefits, such as increased throughput, reduced errors and waste and optimized resource utilization for lowering labor and energy costs.

For example, many paper and pulp processing facilities have upgraded to advanced control systems to maintain proper temperature and pressure as wood chips are pulped. Robotic machinery is now automating the once-manual process of stripping logs of bark and chipping them for pulp preparation.

However, in the paper and pulp industry (and this is the case with many industries), integrating new technology into existing automation systems is not as simple as plug-and-play. Without experienced integrators focused on ensuring the seamless integration of the control systems, the machinery may not perform at optimal levels. This can have downstream consequences, such as lost productivity and wasted resources spent on repairing and maintaining poorly configured machinery.

Mitigating these integration risks begins with taking a hard look at existing facility infrastructures and their legacy system configura -

tions, their network capabilities, and their ability to integrate with new technologies to make their operations more competitive.

7 ways to mitigate risk of a control system upgrade

Here are seven key planning considerations and challenges manufacturers are facing when integrating new automation technologies into an existing facility and some solutions to address them: Current control system configurations, network capability and functionality, machine safety and compliance, end-user experience, compatibility risks, downtime challenges, change management and workforce training. See more on each below.

1: Current control system configurations

While there are many potential long-term benefits from brownfield PLC/DCS upgrades, most end users are primarily concerned with ensuring their production line will run the same way as it did before the system upgrades. This is why it is important to educate end users about any specific changes that will be required for a control system upgrade. This may require a baseline understanding of how the legacy controls equipment functioned before the upgrades. Experienced system integrators can help by with an onsite assessment.

2: Network capability

A common mistake with brownfield system integrations is assuming that the current network is ready for an upgrade. A manufacturer’s legacy equipment may be communicating over a protocol that they want to upgrade so they can put more devices on Ethernet. There is an assumption that they can “just put it on the network” and keep adding devices ad hoc. New automation integrations are rarely as simple as adding a device. The process requires assessing and documenting current network capabilities to determine if the network is effectively working with the facility’s current equipment configuration and if it has the capacity to scale in the future. The planning phase should include assessing how the entire network of equipment will function with the upgraded automation system.

FIGURE 1: Here are seven key planning considerations and challenges manufacturers are facing when integrating new automation technologies into an existing facility. Article provides some solutions to address them. Images courtesy: Eosys

3: Machine safety and compliance

With new automation integrations, there is often a tendency to install the new equipment into the same safety system that was there before. However, the new system may require complex, hardwired circuitry. This could cause issues, such as the safety system failing to reset when new equipment is installed. And there are always potential safety risks with new systems that will perform differently. There is also a common assumption that legacy equipment is up to current safety standards. This is why it is a good idea to have an integrator do a risk assessment before replacing obsolete equipment.

4: The end-user experience

One of the benefits of integrating new controls automation is that it makes it easier for a new generation of manufacturing technology end users to become comfortable troubleshooting issues, such as hardwire systems that could pose safety risks. With many young workers more comfortable with smart phones and tablets than hands-on electronics and maintenance, why not make interfaces more comfortable? Some legacy systems may not even have an operator interface, such as a visual screen where the end user can view machine diagnostics. Fortunately, there have been many advancements in operator interface screens, such as 3D imagery for virtual troubleshooting. The end user should be able to look at the screen and quickly determine if the system is running to spec. A control systems upgrade offers an opportunity to review alarm rationalization and work towards an ISA18.2 compliant system.

5: Compatibility risks for control systems

Very few automation upgrades and PLC/DCS integrations are as simple as plug-and-play, especially when it comes to legacy system compatibility. In the planning phase, a systems integrator will conduct a risk assessment to determine if there are compatibility risks at the machine level, the electrical level or with the current operating system.

6: Downtime challenges

With any new automation integration there are always downtime risks. In a factory setting with multiple production lines that are making the same product, it is easier and faster to complete a new integration. But if there is a production line that is a feeder to other product lines, it is important to find ways to minimize that downtime. Adding more bodies and electricians is not always a solution, especially when working with limited space, such as when it is necessary to rewire a two-by-two-foot panel. Fortunately, integrators can employ multiple methods in the planning phase to

3: Site risk assessments for control system upgrades may include simulations to mitigate risks.

reduce downtime, such as staging kits with pre-wired panels that can quickly be installed to replace current wiring. There are multiple ways to stage new equipment and roll inputs on the fly. It is also important to have a fallback plan that is tested and ready to go. Good planning can significantly reduce downtime and related costs.

7: Change management, workforce

A detailed change management plan is key to a successful automation integration. The plan should clearly define goals and identify employees who will be impacted by the change. What are the expectations of the new automation? Increased productivity, cost reduction or improved quality? How will the workflows change? It is important to answer all these questions before a new system upgrade. Integrators can develop a formal training program that may include digital twins to simulate the upgraded system. Training simulations can ensure quality, which is paramount in particular industries, such as food processing. With a single simulation, employees can learn how to confirm proper amounts of ingredients are added to a batch and that temperatures and other conditions are optimal.

A solid systems integration partner can help find answers for a successful automation upgrade. GSIR

Chase Davis is director of technology, Eosys. Edited by Mark T. Hoske, editor-in-chief, Control Engineering, WTWH Media, mhoske@wtwhmedia.com.

Objectives Learningu

KEYWORDS: Control system integration, automation upgrades, project management CONSIDER THIS

Have you planned your next automation and controls upgrade? ONLINE

With this article online, see more on each of the 7 areas and other important steps to mitigate integration risks. https://www.controleng. com/7-ways-to-mitigatebrownfield-automationintegration-risks/

FIGURE 2: Rewiring control panels, often tight quarters, can go faster with staging kits and pre-wired components.

FIGURE

Nitin Gupta, Sean J. Phillips and Angelo Rabano, Hargrove Controls & Automation

The challenges of legacy systems and benefits of new technology in DCS migration

How one chemical plant navigated a complex control system upgrade to improve safety, efficiency and future readiness.

FIGURE 1: The new hardware improves reliability and flexibility for future expansion while maintaining a small form factor through swappable cards. Images courtesy: Hargrove Controls & Automation

Objectives

• Understanding the challenges of legacy systems and learning how to overcome them.

• Learning the many different phases of DCS migration.

• Understanding how a successful DCS Migration can benefit manufacturers.

Achemical manufacturing plant faced an impending loss of support for the distributed control system (DCS) used in one of its manufacturing facilities, prompting them to upgrade to a new control platform. They turned to Hargrove Controls & Automation to help plan and execute the challenging migration, including the need to keep specific critical safety and process I/O online throughout the changeover.

A chemical manufacturing plant produces organic compounds that serve as the basis for a wide range of industrial and consumer products. Until recently, this plant was operating with a DCS that dated back to the 1980s. While the legacy system was effective for controlling the process, its outdated interface and operating system made it difficult to use. Finding personnel who had experience with the old DCS had also become challenging due to hardware and software obsolescence.

When the chemical manufacturing company learned that support for the old DCS would soon be discontinued, they decided to migrate to a newer DCS platform. Not only would the new system be more user-friendly and improve operator efficiency, but it would also make it easier to find operators and maintenance personnel who had experience with the plant’s control system.

With an experienced team of process engineers, programmers and project managers, Hargrove was able to guide the entire migration, from the field study to post-startup support, ensuring that each phase ran smoothly and efficiently.

Getting to the “heart” of the system

The first step was to develop a functional design specification (FDS), which outlined the design of the entire system, including hardware, software and the control narrative for the process. Creating a functional design specification also helped bring to light items that could pose a challenge during the

migration and allowed the team to address those up-front.

The control narrative, which is a core part of the functional design specification, is considered the “heart” of the system. Project managers and programmers put special emphasis on understanding the plant’s processes and functions to ensure the control narrative was complete and accurate for a smooth migration.

Because the legacy DCS had been in place for several decades, the control narrative was also used as a middle point between the legacy platform and the new one. In other words, as the new control platform was being prepared and implemented, it was validated against the control narrative, rather than the legacy system itself. This made it easier to troubleshoot any issues and verify the new system’s functionality.

One challenge that arose when creating the control narrative was obsolete legacy code. Over time, various pieces of code had been added and then later disabled. For example, the disabled code might have been used for a short-term testing scenario or for an instrument that had since been removed. Regardless of the reason, this unnecessary code made the control program difficult to interpret and troubleshoot. It was necessary to fully understand the customer’s process to successfully identify and remove the inactive code, providing an accurate control narrative.

The migration: Keeping critical I/O running seamlessly

Once the functional design specification, including the control narrative, was approved by the client, this became the guide for programming and setup of the new DCS platform, which presented several more obstacles.

The first step was to ensure that multiple I/O points for safety systems or critical processes remained active during the estimated 10-day cutover

“With secure VPN access, the team edited the database to update I/O points and documentation.“

period. To address this issue, the Hargrove team performed a “hot cutover” of the critical I/O.

For the hot cutover items, the team installed the new DCS I/O for the critical systems and then ran this new I/O in parallel with the legacy system as they spun up, or commissioned, the full, new DCS platform.

This approach ensured uninterrupted operation of the critical safety and process I/O throughout the migration. The remaining I/O followed the standard conversion process. For this part of the migration, integrators accessed the chemical manufacturing company’s smart plant instrumentation (SPI) database, which serves as the plant’s centralized repository for instrumentation data rather than relying on traditional CAD drawings. The team obtained secure VPN access and edited the database directly to update I/O points and associated documentation. This approach ensured accurate verification of I/O connection points while streamlining the process, allowing them to avoid lifting and landing the I/O for items not included in the hot cutover.

The result: A user-friendly DCS capable of Industry 4.0 integration

When migrating from a 40-year-old control system to a new, modern platform, the most apparent and immediate benefit is user-friendliness. Case in point: For this migration, the new DCS platform provided a significant upgrade to the human machine interface (HMI). The new HMI is based on the abnormal situation management (ASM) standard, which provides more intuitive and visible alarms and warnings so operators can make decisions and act quickly, potentially avoiding downtime in a process or operation. The new DCS has also reduced both routine and unplanned maintenance requirements. Implementing the new system also opened possibilities for Industry 4.0 integration that were difficult or, in some cases, impossible with the legacy system. Considering the costs and resources that the migration necessitated, it could have been tempting for the chemical manufacturer to write a program to convert their control code over to a new system. But newer systems that support digital transformation and Industry 4.0 initiatives offer significant

benefits for operational efficiency and effectiveness over the long term, providing additional justification for the project.

Along with the successful startup of the new DCS platform, providers can offer several value-add services that support both the migration and the ongoing operation of the new DCS platform. Hargrove partnered closely with the chemical manufacturing company to help specify, validate and procure the necessary vendor hardware and software. Creating a single point of contact between the chemical manufacturer and vendor helped streamline procurement, ensure compatibility of system components and provide a more cost-effective solution than direct procurement alone.

They also developed documentation related to the migration and operation of the new system, including loop sheets, hot cutover procedures and drawings. In addition, the team provided hardware for the operator training system, so new employees now have the necessary resources to learn, operate and troubleshoot the new DCS platform. GSIR

Nitin Gupta, C&A Petrochemical West, automation leader; Sean J. Phillips, P.E. (AL), senior project manager; Angelo Rabano, C&A engineer all with Hargrove Controls & Automation, a CSIA Certified Member; CSIA is a WTWH Media content partner. Edited by Gary Cohen, senior editor, Control Engineering, gcohen@wtwhmedia.com.

Insightsu

DCS migration insights

u A plant needed to migrate from its obsolete 1980s DCS to a modern system to avoid loss of support and improve usability.

u Hargrove managed the migration by creating a detailed functional design specification, cleaning legacy code and performing a seamless “hot cutover” to keep critical I/O running.

u The new DCS provided user-friendly interfaces, reduced maintenance and enabled Industry 4.0 integration, delivering long-term efficiency and training benefits.

FIGURE 2: A controls engineer performing testing.

Amit Chadha, L&T Technology Services (LTTS)

GenAI in product, manufacturing design: New frontiers

GenAI for product design and manufacturing design can redefine every phase by leveraging large datasets, simulating complex scenarios and generating actionable insights. GenAI helps production lines to run efficiently and actively learn in real time to reduce errors and delays.

The rise of generative artificial intelligence (GenAI) could well be the chance to redefine legacy product development journeys into something faster, smarter and more agile. Product development lifecyle (PDLC), once a slow, resource-heavy process, can now be a high-tech collaboration between humans and AI, reshaping how we design, build and deliver nextgen offerings.

With its ability to amplify creativity and accelerate time-to-market, GenAI is starting to enable global product leaders to set new benchmarks in efficiency, quality and customer experiences. GenAI adoption in PDLC for scaling new frontiers requires a well-thought-out application framework, combining human expertise with a balanced approach that unlocks new value streams.

Rethinking PDLC using GenAI

Learning

u

Objectives

KEYWORDS: Generative artificial intelligence, product design, manufacturing design

CONSIDER THIS

How is GenAI help your product and manufacturing design efficiency?

ONLINE

See other Control Engineering AI coverage. https://www. controleng.com/ ai-and-machine-learning

PDLC is a multi-stage marathon, from advanced engineering and concept creation to the final product launch, and traditionally, has been a meticulous and time-heavy pursuit. GenAI in PDLC acts as a turbo boost, redefining every phase by leveraging large datasets, simulating complex scenarios and generating actionable insights on the go.

Accelerating advanced engineering

The first stage of development journey gets a massive upgrade with GenAI. Picture brainstorming sessions where ideas come not just from minds in the room but also from a powerful AI system that can process infinite possibilities. It identifies overlooked opportunities, optimizes design verification plans (DVPs) for unmatched technical precision, and helps product manufacturers spot innovation points early on.

Step aside evolution; it is time for a creative supercharge!

Redesigning the concept development process

Designing products, not surprisingly, is often seen as sculpting perfection with endless revisions. But now with GenAI, we can eliminate much of the guesswork by directly feeding structural and functional prompts into cutting-edge design systems. The result – designs that meet and exceed performance goals with the need for minimal tweaking.

What we are witnessing is a new paradigm of design fast-tracked, aligning innovation with consumer expectations in ways only dreamed of previously.

Smarter simulations with CAE and CFD

Simulation tools like computer-aided engineering (CAE) and computational fluid dynamics (CFD) often play a key role in predicting product performance across parameters. With GenAI, we find enhanced effectiveness across these tools and a marked decline in analysis times, especially in the automotive segment. AI powered design tools like CAD Systems significantly streamline workflows and reduce timelines. Designers can generate solution-meeting performance goals by inputting structural and functional prompts. This approach minimizes manual iterations, aligning innovations with customer needs faster and with greater accuracy.

Consequently, GenAI-equipped PDLC leaders, stand to gain significant savings in time and resource consumption, while improving on the precision of crucial metrics like noise, vibration, harshness (NVH) and durability.

Manufacturing lines that learn

The impact of GenAI extends beyond the drawing board, transforming how products are manufactured. Think of production lines that run efficiently and actively learn in real time to reduce errors and delays. By deploying AI-powered predictive algorithms, manufacturing systems can anticipate component failures, optimize machine settings and

“GenAI is redefining how products are imagined, developed and refined across industries, creating new opportunities that seemed impossible just a decade ago, said Amit Chadha is CEO and managing director, L&T Technology Services (LTTS).“

Courtesy: L&T Technology Services (LTTS)

minimize downtimes. GenAI use leverages live data to fine-tune production strategies, ensuring seamless processes and delivering a final product that exceeds expectations.

GenAI, used correctly, always finds new ways to improve.

Three steps to unlocking GenAI for PDLC

While GenAI may continue to feel like science fiction comes to life, getting it right takes more than just flipping a switch. Challenges, like the infamous “hallucination” effect (AI generating incorrect or misleading outputs), mean automakers need to stay vigilant. Without human oversight, innovation can veer off course. A three-step approach can help:

• Expert oversight: Involving skilled and trained professionals in the GenAI-enabled PDLC journey can help ensure that the output aligns with market demands and real-world usability.

• Blend AI with consumer insights: Merging AI predictions with customer feedback can provide a more complete picture of preferences and needs.

• Stay ahead of trends: All AI models learn from the past, but markets continue to evolve. As a result, the teams today need to be agile for ensuring that GenAI insights are relevant, even under evolving consumer expectations.

By addressing these elements, manufacturers can unlock the full spectrum of GenAI’s potential without losing sight of the human touch, and reinforce how AI enhances performance, safety and efficiency while letting creativity soar.

Four ways GenAI helps manufacturing GenA use in manufacturing includes:

• AI assistants: Precision tools help develop concepts faster with fewer errors.

• CAD and AI: Generating smarter, optimized designs while cutting down endless iterations.

• Supercharged simulations: CAE and CFD powered by AI analyze data faster, improving outputs by up to 70%.

• Streamlined manufacturing: Real-time insights reduce delays, align workflows and deliver projects ahead of schedule.

By incorporating cutting-edge tools and analytics, manufacturers can therefore build brand loyalty, innovate persistently, and unlock sustainable operational success.

Plan your next move in the GenAI revolution

GenAI is redefining how products are imagined, developed and refined across industries, creating new opportunities that seemed impossible just a decade ago. For manufacturers and product design leaders eager to scale new heights, with the right blend of human expertise and advanced AI tools, the emphasis is on creating means and experiences that inspire loyalty and set benchmarks.

Is not just about staying competitive, but about leading into the future, with innovation as your co-pilot. GSIR

Amit Chadha is CEO and managing director, L&T Technology Services (LTTS). Edited by Mark T. Hoske, editor-in-chief, Control Engineering, WTWH Media, mhoske@wtwhmedia.com.

Timothy Mullen, OT Cybersecurity Team Lead, Applied Control Engineering

Cybersecure by design: the often-overlooked pillar of smart manufacturing

Why manufacturers must embed cybersecurity into system design to ensure smart operations are resilient, reliable and ready for tomorrow's threats.

ALearningu

Objectives

• Recognize the role of cyber-informed engineering (CIE) in designing operational technology (OT) systems that are cybersecure by design, not by retrofit.

• Understand how to leverage the ISA/IEC 62443 Automation Solution

Security Lifecycle as a framework for embedding cybersecurity into control system engineering practices.

• Identify key design strategies — such as earlystage risk assessment, security zoning and disaster recovery planning

— that enhance OT system resilience.

CONSIDER THIS

Is cybersecurity treated as a core design requirement in your organization — or is it still an afterthought that leaves smart manufacturing systems exposed?

s manufacturers integrate new technologies across the plant floor, cyber threats are escalating just as fast. Too often, cybersecurity for operational technology (OT) assets is addressed after deployment, or worse, after a breach. But in today’s highly connected plant floor environment, this type of reactive model is no longer sufficient.

Instead, true protection demands a proactive approach where cybersecurity is embedded into system design from Day One. By applying the principles of cyber-informed engineering (CIE), which emphasize the integration of cybersecurity considerations into every phase of system design and operation, manufacturers can ensure their smart systems are resilient from the start.

Why reactive cybersecurity is no longer enough

In Deloitte’s 2025 Smart Manufacturing and Operations Survey, the organization found that 68 percent of respondents had conducted a cybersecurity risk or maturity assessment in the last year, yet 91 percent still experienced a breach. This disconnect seems to highlight a deeper issue — while compliance exercises are broadly accepted, the hard work of actual security implementation is still a challenge.

To prevent these issues from further escalating as new technologies are implemented on the plant floor, manufacturers must make cybersecurity a core component of their system design. But despite this reality, only 26 percent of manufacturers surveyed say they enforce secure-by-design principles when implementing new technologies, and they do it only when it doesn’t delay deployment. In other words,

cybersecurity is still being sidelined in favor of speed and productivity, even if the reality is that inadequate cybersecurity can greatly hinder these metrics when a breach occurs.

The case for cyber-informed engineering

To build resilience into modern manufacturing systems, manufacturers must shift from typical reactive cybersecurity practices, where security measures are not implemented until systems are installed, to a proactive CIE approach. This method recognizes cybersecurity as an essential system requirement, just like performance or reliability, that must be integrated into the conception, design, development and operation of any physical system.

More specifically, CIE focuses on shaping system behavior to limit an adversary’s ability to cause harm, even if a breach occurs. Key principles of CIE include:

• Consequence-driven design: Identify what could go wrong if a system is compromised and eliminate or reduce that risk at the design level.

• Secure architectural segmentation: Isolate high-consequence assets in ways that limit cyberattack paths using zones and conduits.

• Fail-safe design: Ensure systems default to safe modes under anomalous or unauthorized activity.

• Cyber-physical awareness: Recognize that actions in the digital world have real-world, physical consequences.

When the principles of CIE are applied to the design of smart manufacturing equipment, the resulting systems are inherently secure — or, in other words, cybersecure by design. In short, this means:

• Cyber risks are identified and addressed early.

• The system architecture supports security objectives.

• Technical and organizational security controls are part of the base design.

• Recovery, monitoring and resilience are designed into the system, not bolted on afterward.

Let’s now dive into how to leverage the framework identified in the ISA/IEC 62443 series of standards to ensure systems are cybersecure by design.

Using ISA/IEC 62443 to build security into the system lifecycle

The Automation Solution Security Lifecycle as defined in ISA/IEC 62443 aligns directly with the principles of CIE and provides a detailed framework for engineering cybersecurity into industrial automation systems. By mapping out the phases and responsibilities for the key stakeholders of an automation solution — this includes asset owners, system integrators, product suppliers and maintenance providers — this standard helps ensure cybersecurity is adequately addressed throughout every phase of the system lifecycle.

This lifecycle includes seven phases: specification, design, implementation, verification and validation, operation, maintenance and decommissioning. However, for the purposes of this article, we will focus on the first four phases (Figure 01).

Specification

• Perform an initial, high-level cybersecurity risk assessment of the risks that will exist for the system being designed.

“Appropriately configure all layers of the defense-in-depth approach, so that a failure of a single layer does not result in failure of the overall protection.“

• Partition the system into zones and conduits, which allows security requirements to be tailored and contained and creates baseline security boundaries.

• Specify the target security levels (SL-Ts) for each zone/conduit.

Design

• Conduct detailed risk assessments for each zone and conduit.

• Identify ways to eliminate digital pathways to high-consequence failure modes.

• Define technical security measures that implement protections meeting the SL-Ts.

• Define organizational security measures to address human factors and when technical limitations require compensating controls.

• Document the cybersecurity requirements specification, which must be approved by the asset owner before implementation begins.

Cybersecure by design: the often-overlooked pillar of smart manufacturing

Implementation

• Integrate the system components according to the security design.

“

With every new sensor, controller or cloud connection, the attack surface grows, and so does the urgency to rethink how cybersecurity is approached.“

• Appropriately configure all layers of the defense-in-depth approach, so that a failure of a single layer does not result in failure of the overall protection.

• Apply product security updates during installation.

• Develop supporting organizational procedures for operations and maintenance phases.

Verification and validation

• Conduct tests to ensure all technical security requirements have been met.

• Perform vulnerability assessments and erify access controls.

• Complete formal handover to operations, including credential changes and asset owner validation.

In summary, following the Automation Solution Security Lifecycle as defined in ISA/IEC 62443 can help you design systems using the CIE method since risk assessments are conducted early and revisited regularly, systems are partitioned into zones and conduits to manage and contain cyber threats and security levels are defined, validated and maintained throughout the lifecycle of your system.

The benefits of having cybersecurity as a design requirement

Adopting a cybersecure-by-design mindset is more than checking a box. It’s about making sure the system you’re designing can inherently identify, protect, detect, respond and recover — the core NIST Cybersecurity Framework function — without relying on stopgap controls or manual workarounds. When done right, cybersecure-by-design systems:

• Sustain uptime by minimizing disruption risk.

• Protect intellectual property and sensitive data.

• Accelerate deployment by reducing the need for retroactive fixes.

• Align with standards like NIST 800-82.

• Support long-term productivity and continuous improvement.

Designing for resilience in the age of smart manufacturing

As manufacturers modernize operations, the digital transformation of the plant floor cannot come at the cost of cyber resilience. With every new sensor, controller or cloud connection, the attack surface grows, and so does the urgency to rethink how cybersecurity is approached.

Embracing the CIE method and the ISA/IEC 62443 Automation Solution Security Lifecycle can provide manufacturers with a practical, standards-based path to shift from reactive defenses to proactive design. When they are applied together, cybersecurity can be approached as an embedded, enabling element of your smart manufacturing efforts. By engineering systems to be cybersecure by design, manufacturers not only reduce risk, but also gain the confidence to innovate faster, operate more reliably and build a foundation that can withstand both digital and physical threats. GSIR

Timothy Mullen, PE, is an OT cybersecurity team lead at Applied Control Engineering Inc. (ACE), a CSIA member; CSIA is a WTWH Media content partner. Edited by Gary Cohen, senior editor, Control Engineering, gcohen@wtwhmedia.com.

Insightsu

Cybersecure by design insights

u Cybersecurity must be built into OT systems from the start — not added after deployment — using a proactive, cybersecure-by-design approach grounded in cyberinformed engineering (CIE).

u The ISA/IEC 62443 Automation Solution Security Lifecycle offers a practical framework for applying CIE principles throughout the system lifecycle, ensuring security is integrated at every phase.

u Designing for cybersecurity from Day One improves resilience, minimizes downtime, protects sensitive assets and supports faster innovation and deployment in smart manufacturing.

Clint Bundy, Bundy Group, Charlotte, North Carolina

How to unpack 2025's system integration M&A market

Bundy Group is an investment banking and mergers and acquisitions advisory specialist that has specialized in the automation and control system integration markets for over 16 years.

Heading into 2025, the mergers and acquisitions (M&A) market was positioned for a strong year, and the first quarter of this year did not disappoint. However, the broader economy and geopolitical landscape presents challenges for the overall M&A market, and it raises questions about whether there will be a negative impact on the robust control system integration M&A market for the remainder of 2025 and into 2026.

To provide clarity on this evolving market, we start with a real-time assessment of broader market conditions — offering essential context for emerging trends in the control system integration segment.

Complementing this market snapshot, also see an update on the control system integration M&A market and the broader automation solutions M&A market.

The North American M&A market

Business owners considering a sale or acquisition should understand the recent M&A market cycle. In 2021, North American M&A activity reached an all-time high of $2.7 trillion, driven by low interest rates, a backlog of deals from the pandemic, and strong buyer demand.

Activity cooled in 2022 and 2023, as rising interest rates and greater caution from buyers led to a decline in deal flow — dropping to $1.8 trillion by 2023, according to PitchBook.

Encouragingly, 2024 brought renewed momentum in terms of transaction activity. As buyers adjusted to the higher rate environment and became more active, 2024 transaction value climbed roughly 16% over the prior year, reaching $2.0 trillion (see Figure 1).

Through the second quarter of 2025, North American mergers and acquisitions (M&A) activity reached a total transaction value of $596.8 billion across nearly 4,500 deals, according to PitchBook.

Although deal value dipped 3.2% from Q1 to Q2, it represented a robust 31.3% year-over-year increase. This strong performance in the first half of 2025 was largely driven by several factors:

• A resurgence of large-scale corporate transactions

• Continued momentum in the technology sector and related sub-verticals

• Increased confidence among dealmakers that macroeconomic challenges were unlikely to trigger a near-term recession

• An increase of add-on transactions, which were approximately 76% of all deals through Q2 2025 - a substantial difference from the fiveyear add-on average of 72.5%

Please note: The information and content in this article reflect conditions and data as of July 2025, the time of writing.

FIGURE 1: The North American M&A market results as of June 30, 2025. All figures courtesy: The Bundy Group

How to unpack 2025's system integration M&A market

Despite strong momentum carried over from 2024, transaction professionals remain cautious, carefully monitoring macro-level risks such as global trade tensions and geopolitical instability that could influence the M&A landscape. While Bundy Group continues to specialize in the control system

integration and automation solutions sectors, we’re also observing steady buyer demand across other business services and tech-enabled services verticals. At the same time, seasoned acquirers are exhibiting heightened discipline in their evaluation of opportunities, with a clear emphasis on understanding how broader economic conditions may affect backlogs, revenue projections, and overall deal viability.

The control systems integration M&A market

Over the past 15 years, Bundy Group has consistently witnessed strong momentum in the M&A market for control system integration companies. This growth is driven by several key factors: the sector’s inherent resiliency, ongoing market expansion, a highly fragmented integrator landscape, and the compelling investment returns achieved by groups that have acquired, scaled, and successfully exited control system integration firms.

As illustrated in the two charts below (see Figure 2 and Figure 3), both the control systems integration M&A market and the broader automation solutions space continue to experience a robust pace of transaction activity — clear evidence that buyers and sellers remain highly active in these segments.

Bundy Group’s ongoing work within the control system integration sector gives us a unique vantage point to share proprietary market insights. Recent transaction experience includes the successful sale of three control system integration companies — CITI, EPIC Systems and Compass Systems — in the past eight months alone (see Figure 4). Our client engagements, along with our current mandates in the space, offer key takeaways for business owners and investors evaluating opportunities in this dynamic market.

Takeaways from the control system integration M&A market

There are quite a few takeaways from 2025’s control system integration M&A market.

Robust buyer demand: Control systems integration firms remain highly sought after by both financial sponsors (that is, investors) and strategic buyers (such as operating companies seeking add-on acquisitions). Buyer demand continues to outpace supply, particularly for high-quality control system integration businesses-creating a competitive environment that favors sellers.

FIGURE 2: Total number of control system integration M&A transactions.

FIGURE 3: Total number of automation M&A transactions.

Buyer separation: Sophisticated financial sponsor and strategic buyers in the control system integration market seek to thoroughly understand a company before submitting a letter of intent (LOI) or offer. In contrast, opportunistic buyers often bypass early diligence, which can signal a higher likelihood of re-trading on terms or walking away during due diligence. Inherent knowledge of the pool of buyers, and how they perform when the "rubber meets the road," is critical.

International buyer presence: Today’s geopolitical and macroeconomic conditions are accelerating strategic and financial sponsor buyer interest in the North American market. Bundy Group had one control system integration client sell in 2025 to a European-based strategic buyer, and we had another industrial client sell this year to a Japanese-based publicly traded conglomerate. Both buyers were aggressive in their pursuit of the opportunities and in their value / structuring on the respective transactions.

Competition translates to value: We specialize in representing running competitive processes on behalf of our clients in a sale process. We continue to see that no two buyers value a company the same way, and that a competitive process yields the best results. The percentage spread between the highest offer and the lowest offer on five recent control system integration transactions have been as follows:

Automation Client 1: 108%

Automation Client 2: 91%

Automation Client 3: 198%

Automation Client 4: 143%

Automation Client 5: 148%

To illustrate with sample math using a 198% spread: if the lowest offer was $20 million, the highest would be approximately $59.6 million — a $39.6 million difference that highlights just how impactful buyer competition can be in a sale process.

Financial and KPI preparation: Seasoned buyers are more willing to compete and pay higher valuations for companies that are deemed lower risk investments.

A significant factor in determining risk is the depth of financial details and systems that a company has implemented. Further areas of focus include:

• Revenue recognition: An area of great focus and scrutiny in due diligence by buyers. We encourage owners to seek advisor advice (transaction accounting firm; investment banking advisor) on critical items and potential missteps with revenue recognition, including percentage of completion accounting, owners make that can impact value in a sales process.

• Backlog conversion: Since buyers are acquiring the future, they focus mightily on conversion of pipeline to backlog according to company projections. If the company is consistently missing its backlog conversion, then that can create doubt about the company’s future performance.

• Financial controls: Lack of financial controls and systems, which can't support detailed financial requests, increase riskiness of a company in eyes of a buyer. GSIR

Clint Bundy is the managing director of The Bundy Group, a CSIA member; CSIA is a WTWH Media content partner. Edited by Sheri Kasprzak, executive editor, Automation & Controls, Control Engineering, WTWH Media, skasprzak@wtwhmedia.com.

FIGURE 4: Control system integration recent transactions. Courtesy: The Bundy Group

• Learn about the system integration mergers and acquisition market in 2025.

• Understand where 2025’s M&A activity compares to that of recent years.

• Unpack key takeaways from 2025’s system integration M&A market.

Sam Hoff and Nikhil Niphadkar, Patti Engineering, Auburn Hills, Michigan

How to overhaul control systems to keep the line and save money

The continued operation of aging manufacturing lines poses a threat to production, safety and cybersecurity. Upgrading the controls system and retaining existing mechanical systems can modernize a line and minimize cost, time and risk.

How long can a production line keep running on outdated control systems?

For many manufacturers, this question’s urgency increases with every unplanned shutdown and each unavailable spare part.

Plant managers are aware that intermittent downtime, scarcity of spare parts, cybersecurity risks and limited integration capability are some of the challenges associated with operating older control systems. However, they are also constrained by tight budgets and limited shutdown windows, each impacting their ability to improve a line’s overall equipment effectiveness (OEE) metrics.

Objectives Learningu

• Understand how and why control systems degrade and become obsolete much faster than mechanical equipment.

• Evaluate the operational, financial and strategic advantages of targeted control system upgrades, including reduced downtime, lower capital costs and improved production capabilities.

• Identify the essential preparation required for control system upgrades, including documentation gathering, communication protocol reviews, software migration planning and cybersecurity considerations.

When the control system has become obsolete, it’s common for a legacy line’s mechanical equipment to remain in good working condition with many years of serviceable life remaining. As a result, by focusing investment towards upgrading the control system, the entire line can be modernized with far less risk, downtime and cost compared to full replacement. When planned carefully, a controls upgrade can transform line reliability, data visibility and long-term scalability without the expense of starting over.

Aging control systems, a weak link

Why do control systems become the limiting factor in otherwise functional production lines?

The typical life span of various industrial mechanical and control system components (see Figure 1). Devices that incorporate more electronics tend to have shorter operating lives, such as sensors, human machine interfaces (HMIs), programmable logic controllers (PLCs) and variable frequency drives (VFDs), compared to those that have less or none, such as computer numerical control (CNC)

machines, motors/gearboxes and conveyors/presses. This relationship is not coincidental.

Electronics-based controls including PLCs, HMIs and drives degrade over time due to the failure of their small-scale electronic components and assemblies and general obsolescence of internal microchips. Within 10 to 15 years of service, these devices begin incurring increased fault rates and spare parts become hard to obtain. The resulting downtime is often difficult to diagnose and resolve, particularly when the failure is intermittent or associated with low-level hardware issues.

When a module fails, it must be replaced to return the line to production. As control systems age, sourcing these parts becomes progressively more difficult. Within 10 to 15 years of its final production run, original equipment manufacturers (OEMs) eventually cease all spare part support and render the product fully obsolete. At that point, manufacturers resort to eBay-type resellers, raising both cost and risk.

Aging controls create vulnerability

Compounding the issue, OEMs typically discontinue firmware support for legacy systems within a similar timeframe. Without updates, any new cybersecurity vulnerabilities remain unpatched, leaving critical infrastructure exposed.

Finally, aging control systems frequently cannot meet the demands of modern automation. Many cannot support coordinated motion in robotics or packaging lines, nor can they handle real-time data collection for OEE tracking and quality monitoring. As a result, obsolescence not only increases downtime risk but also limits a plant’s ability to modernize.

These factors collectively make legacy control systems the weakest link and the primary target for modernization. Older control system have specific failure mechanisms and obsolescence risks.

Mechanical equipment remains reliable

While aging control systems present numerous complex challenges, it’s common for the line’s mechanical equipment to remain in good condition considerably longer. In fact, the serviceability of a

production line’s mechanical equipment can span multiple control system upgrade cycles.

Consider a conveyor system. Bearings and rollers may require replacement, but the frame, gearboxes and other mechanical drive components often remain in service for decades with routine maintenance.

Degradation of mechanical assemblies tends to be gradual, predictable and easier to manage through standard maintenance practices. Furthermore, mechanical systems rarely become obsolete. When parts such as shafts, couplings or bearings wear out, replacements or repairs are typically straightforward, with parts readily available or able to be fabricated. Many mechanical systems are designed to be overhauled or rebuilt multiple times throughout their service life, often lasting several decades.

Control system upgrade business case

Because a line’s mechanical systems face minimal obsolescence concerns, it can usually be modernized by upgrading the control system. Consider the following benefits of completing controls upgrade over a full line replacement:

• Lower capital cost spread over phases: Replacing the control portions of a production line, including PLCs, HMIs and motor drives is far less costly than installing an entire new line. In addition, when multiple phases are used to complete the upgrade, the project’s cost can be distributed over a longer timeframe, rather than one large upfront investment.

• Shorter project lead time: For a controls upgrade, standard PLCs, HMIs and I/O modules can be sourced and installed much faster than equipment for an entirely new line.

• Reduced disruption to production during installation: Phased upgrades can be aligned with existing shutdown windows, with production resuming between phases. Virtual commissioning techniques allow engineers to digitally test and refine control software in advance, reducing installation risk and downtime.

• Preservation of proven mechanical assets: Maintaining the existing mechanical portions of a production line reduces installation and integration risk and maintains system familiarity for operator and maintenance staff.

• Harvesting of spare parts: As legacy controllers are replaced, their parts can be saved for any other lines still operating the same control systems.

An upgraded control system provides the foundation for modern production line capabilities, including:

• Faster cycle times

• Better diagnostics and troubleshooting information

reflect general industry experience and typical operating expectations. Images

• Remote monitoring and support capabilities

• Better cybersecurity protection

• Access to real-time production data for analytics tools and digital twin development

• Simplified integration with modern SCADA, MES and enterprise systems

Realizing these benefits requires significant planning to ensure the upgrade is successful. The following section outlines key preparatory steps.

Preparation for a controls upgrade

Because a control system’s primary function is coordinating and directing the manufacturing process, a successful upgrade requires a holistic understanding of the existing system. The control system is connected to every element of the production line, including

FIGURE 1: Typical lifespan ranges for common industrial system components. Values

courtesy: Patti Engineering

FIGURE 2: An aging engine assembly line upgraded by Patti Engineering over 15 phases, minimizing impact to production.

How to overhaul control systems to keep the line and save money

mechanical equipment, sensors, HMIs and switches. Preparation for a controls upgrade involves gathering documentation, analyzing the process, planning for software migration and addressing cybersecurity posture, as elaborated upon below.

“

Modern control systems support faster cycle times, robust data collection capabilities, advanced diagnostics and more.“

Communication protocols: Identify all communication protocols used by connected equipment to ensure compatibility with the new PLC and prevent connectivity issues. If any devices are incompatible, identify any protocol conversion gateways that can support the equipment.

Design documents: Obtain existing electrical and mechanical prints to understand how equipment is interconnected within the current system. If the prints are unavailable, physically trace the electrical and mechanical interconnections to map the system.

Sequence of operations: Understand the order of operations within the process. Video recordings of the current system can be used to help understand the existing source code by matching observations with the control logic.

Software migration: Assess whether existing control logic can be translated or should be rewritten. This depends on the code’s quality, clarity and compatibility with the new platform.

Cybersecurity posture: Evaluate the operational technology (OT) network’s current and future cybersecurity needs, especially as modern control systems incorporate remote access, real-time data collection, system monitoring and diagnostics and integration with plant-wide software systems.

Extend the life of a production line

A recent project completed by Patti Engineering demonstrates how a targeted controls upgrade can resolve long-standing issues and extend the useful life of an existing production line.

production. Spare parts for the controls systems were no longer available from the OEM and could only be found via highly unreliable sources –– primarily eBay.

After several multi-day downtimes and expensive emergency support calls to restart the line, the manufacturer recognized that addressing these issues could no longer be delayed.

Phased controls upgrade, software rewrite:

Since the mechanical equipment was in good operating condition, Patti Engineering recommended a targeted controls upgrade with a complete software rewrite and a phased upgrade approach to minimize interruption to production.

Given the line’s size and complexity, Patti Engineering completed the upgrade during 15 phases aligned with scheduled shutdowns, allowing production to resume between installations. Virtual commissioning was used extensively to model and simulate the line’s operation to verify the new software’s functionality ahead of each phase of installation.

Increased uptime, better diagnostics: In addition to eliminating immediate risks tied to obsolete hardware, the upgraded control system resolved the manufacturer’s downtime issues and dramatically improved fault recovery due to better diagnostics. The new control system simplified integration with plantwide platforms.

The case for updating control systems

While legacy control systems pose significant production and cybersecurity risks, full line replacement is not always necessary since mechanical equipment typically outlasts the controls system by decades. By focusing upgrade efforts on the control system, manufacturers can preserve existing mechanical assets while modernizing operations for better performance.

u

Six benefits of modern control systems

u Reduced risk

u Faster cycle times

u Robust data collection

u Andvanced diagnostics, analytics

u Remote monitoring

u Easier integration with plantwide platforms

Downtime, difficult restart, no spare parts: A leading manufacturer’s heavily used, aging engine assembly line was controlled by an older Allen-Bradley PLC and incorporated over 100 independent conveyor sections, 12 robotics stations, plus hundreds of sensors and other additional equipment (see Figure 2).

The manufacturer had been facing an increasing frequency of unexplained downtime. Compounding the issue, the existing controls software did not include sufficient diagnostics or alarming, making troubleshooting difficult. When the line failed, it often took several days to find the underlying cause and restart

Modern control systems reduce risks, support faster cycle times, robust data collection capabilities, advanced diagnostics and analytics, remote monitoring and easier integration with plant-wide platforms. Investing in a controls upgrade improves production reliability and productivity, supports long-term scalability and positions manufacturers for future growth. GSIR

Sam Hoff is founder and chief executive officer; Nikhil Niphadkar is an engineering team lead and senior controls engineer II, both at Patti Engineering. Edited by Sheri Kasprzak, executive editor, Automation & Controls, Control Engineering, WTWH Media,skasprzak@wtwhmedia.com.

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.

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.

Collaboration is what the Software Toolbox experience is about.

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.

Win Worrall Partner Program Manager

Software Toolbox Inc.

Email: wworrall@softwaretoolbox.com

Telephone: 704-849-2773

Charlotte, NC

SYSTEM INTEGRATORS SPONSORED BY SOFTWARE TOOLBOX

SKYiO

System Integrator Corporate Close-Ups

Audubon Companies

AUDUBON IS YOUR GO-TO PARTNER FOR INTEGRATED, FULL-SCALE AUTOMATION SOLUTIONS.

At Audubon Companies, we provide end-to-end system integration solutions that help our clients operate smarter, safer, and more efficiently. As a platform-agnostic service provider, we design, implement, and support automation and control systems tailored to the unique needs of your site and your operations.

Our approach integrates critical services under one roof—from engineering, design, and fabrication to full EPC and MAC. With a 20,000-ft2 climate-controlled integration space and 24,000-ft2 fabrication and storage facility, we can manage complex projects from concept through commissioning, ensuring seamless execution and accountability at every stage.

Collaboration and flexibility are at the core of our work. We partner closely with our clients, delivering solutions that prioritize people, processes, and technology to drive real results. Whether it’s upgrading your network security or migrating to a new control system, we bring the scale, experience, and precision to succeed.

Audubon Offices:

• Houston, TX

• New Orleans, LA

• Lafayette, LA

• Midland-Odessa, TX

Automation & Control Capabilities

• Implementation & integration

• Migration & upgrade

Primary Industries:

• Onshore Oil & Gas

• Offshore Oil & Gas

• Orange, TX

• Tulsa, OK

• Pittsburgh, PA

• Ludington, MI

• San Ramon, CA

• Bogotá, COL

• México City, MEX

• Virtualization & cybersecurity

• Optimization & support

• Turnkey EPC & MAC

• Petrochemicals & Refining

• Power & Utilities

• Manufacturing & Infrastructure

Audubon Companies

3505 W. Sam Houston Pkwy. N., Ste. 150 Houston, TX 77043 281-669-0590

• Sales@AudubonCompanies.com www.auduboncompanies.com

System Integrator Corporate Close-Ups

GLOBAL RELIABILITY. LOCAL COMMITMENT. PROVEN RESULTS.

GreyLogix is a global trusted partner, advising and delivering engineering excellence for industries in more than 30 countries across every continent. Our clients choose us because we never settle – we deliver. With every project, we focus on performance, quality, and value that consistently exceeds expectations. With decades of engineering expertise, we blend innovation and pragmatism to design solutions that work – everywhere. From complex industrial challenges to mission-critical environments, our proven track record demonstrates one thing: reliability isn’t optional – it’s embedded in everything we do. What truly sets us apart is more than our global reach – it’s our ability to deliver world-class capabilities with an exceptional cost-benefit ratio. We ensure every partnership drives measurable, lasting results – without compromise. At GreyLogix, our commitment goes beyond technology. We build long-term partnerships based on trust, transparency, and delivery. Wherever your operations are, count on us to transform challenges into results. GreyLogix – we DESIGN, we DELIVER! And we make IT SMART.

CONTACT INFORMATION:

Renato Leal leal@greylogix.us

System Integrator Corporate Close-Ups

Hargrove Controls & Automation

YOUR GUIDE TO INDUSTRIAL AUTOMATION Safe Solutions. Reliable Systems. Sustainable Results.

As a leading system integrator, Hargrove Controls & Automation is one of few multidiscipline automation groups in the country capable of providing turnkey solutions for plant automation, safety systems, cybersecurity/OT, and industrial digitalization. Our system integration Team provides simplified solutions for our clients by working handin-hand with the engineering and execution Team throughout the project life cycle.

Our Team specializes in DCS/PLC/SIS system integration & migration, digitalization, and process safety. We can implement the vision of Industry 4.0 through digitalization such as AI-enabled advanced process control, equipment failure predictions, reliability and availability analyses, and multi-variate analysis. Our Process Safety Team of TÜV Rheinland Functional Safety Engineers has many years of experience in all phases of the process safety lifecycle including Process Hazard Analysis, SIL Calculations, Safety Requirement Specifications, and SIS logic solver programming. We provide process safety training courses, and we host TÜV Rheinland certification courses facilitated by authorized providers.

Hargrove Controls & Automation implements control systems for pulp & paper, petroleum & chemical, heavy manufacturing, and other industrial facilities. Our Team consists of process control engineers and specialists, certified process safety engineers, cybersecurity professionals, networking specialists, instrumentation designers, and panel builders. We foster 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.

Together, Hargrove and Tormod offer clients a differentiator in the marketplace by providing a complete solution for total asset life cycle management including engineering, automation, full-service EPC, maintenance, reliability, commissioning & startup, and technical services. Tormod specializes in transitioning engineered facilities into operating assets with both short-term commissioning assistance and longterm operations contracts. The success of our Team of companies stems from cultivating the most talented engineering and construction professionals while valuing long-term client relationships.

For more information about Hargrove Control & Automation, please visit https://hargrove-ca.com . For more information about Tormod, please visit https://tormod.com/.

Capabilities

• System Integration

• System Migration

Corporate Headquarters

Mobile, Alabama / 251.476.0605

KEY EXECUTIVE

Karen Griffin, Vice President Hargrove Controls & Automation

• Process Safety

• Machine Safety

Other Office Locations:

• Angleton, TX

• Atlanta, GA

• Baton Rouge, LA

• Beaumont, TX

• Birmingham, AL

• Columbus, OH

• Concord, CA

• Decatur, AL

• Greenville, SC

• OT/Cybersecurity

• Digital Transformation

• Houston, TX

• Lake Charles, LA

• Memphis, TN

• Monterrey, MX

• Pasadena, TX

• Pascagoula, MS

• Philadelphia, PA

• Savannah, GA

• Mexico City, MX

CONTACT INFORMATION:

• Panel Fabrication

• Lifecycle Services Solution

Nick Hausman, Marketing Leader

Hargrove Engineers & Constructors | Controls & Automation Life Sciences | Tormod | p: 251.375.5924 | c: 618.954.9071

www.hargrove-epc.com

System Integrator Corporate Close-Ups

OMNICON SHAPES THE FUTURE OF GLOBAL MANUFACTURING THROUGH INNOVATION, INTEGRATION, AND DATA-DRIVEN EXCELLENCE WORLDWIDE

Founded more than 33 years ago, Omnicon has evolved into a leading global system integrator with a strong presence in the United States, Latin America, and operations in more than 65 countries worldwide. The company specializes in multi-plant implementations for multinational manufacturers, starting every engagement with a deep understanding of operational needs to define a standardized and unified model that can be replicated across sites and regions with agility and consistency. Its expertise covers engineering, manufacturing operations management, process control, IIoT, and data analytics, delivering integrated solutions that enhance efficiency, traceability, and sustainability. With deep specialization in batch process control and data management, Omnicon enables manufacturers to unify systems, standardize information layers, and transform operational data into actionable insights through advanced analytics. Omnicon’s consultative and collaborative methodology allows global organizations in industries such as food & beverage, consumer packaged goods, chemical, pharmaceutical, mining & cement, oil & gas, and utilities to achieve operational excellence and accelerate their digital transformation journeys.

Recognized as a CSIA-certified system integrator and one of Deloitte’s Best Managed Companies for five consecutive years, Omnicon continues to move global manufacturing beyond technology.

Corporate Headquarters:

• Cali, Colombia

Capabilities:

• MES/MOM

• INDUSTRIAL DIGITAL TRANSFORMATION

• PROCESS MAPPING & DIGITALIZATION

• IIOT

Primary Industries:

• Food and Beverage

• Chemical

Other locations

• Pembroke Pines, FL

• Houston, TX

• CONTROL SYSTEMS INTEGRATION

• PROCESS AUTOMATION

• BATCH SOLUTIONS

• SYSTEM MIGRATIONS

• Oil & Gas

• Pharmaceutical

• Queretaro, MX

• Valencia, ES

• INDUSTRIAL AI

• DATA MANAGEMENT

• REPORTS & ANALYTICS

• INDUSTRIAL DATAOPS

• Mining & Cement

• CPG

OMNICON

Jose Montoya, Business Development Manager

Email: jose.montoya@omnicon.co

Phone: +1-210-485-6280 www.omniconint.com

System Integrator Corporate Close-Ups

ROVISYS

PROVEN, STRATEGIC, SUSTAINABLE SOLUTIONS.

Since 1989, RoviSys has been a trusted global leader in automation and information solutions, dedicated to helping businesses improve security, efficiency, and profitability. With decades of experience, the company offers an extensive portfolio of services that includes information management, manufacturing automation, control systems integration, building automation, MES, and Industrial AI. By combining technical expertise with industry knowledge, RoviSys consistently delivers proven, practical solutions that drive real business value.

AUTOMATION AND INFORMATION SOLUTIONS

Globally. Reliably. Effectively.

RoviSys has earned its reputation for excellence by boosting productivity, improving product quality, and maximizing asset utilization. Its customer-focused approach emphasizes quality, reliability, and service, making the company a long-term partner to clients around the world.

Every engagement begins with an understanding of each client’s unique goals and priorities. Whether delivering solutions for organizations with limited budgets or guiding enterprise-wide digital transformation programs, RoviSys aligns technology with business objectives through expert project management, deep technical knowledge, and vendor independence.

As industries and technologies continue to evolve, RoviSys remains committed to driving innovation and delivering results that help clients stay competitive. With a clear focus on value, reliability, and long-term success, RoviSys empowers companies to adapt, grow, and thrive in today’s rapidly changing global marketplace.

Capabilities: Engineering Offices:

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

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

• Europe: Nederland, Ireland

• Process Automation

• Building Automation

• Discrete Manufacturing Automation

• Warehouse Automation

Primary Industries:

• Chemicals

• Life Sciences

• Consumer Goods

• Data Centers

• Glass

• Control Systems Integration

• Manufacturing Execution Systems (MES)

• Industrial Network Solutions

• Building Management Systems

• Mining & Metals

• Oil & Gas

• Paper & Wood

• District Energy & Microgrids

• Water/Wastewater

• Electrical Power Management Systems

• Electrical & Instrumentation Design

• Industrial AI

• Consulting

• Semiconductor

• Automotive

• Federal Solutions

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

Wunderlich-Malec Engineering, Inc.

Partner With The Experts In Advanced Engineering

Wunderlich Malec Engineering is a national leader in advanced automation, control, and multi-disciplined professional engineering. We unite our expert electrical, mechanical, civil, structural, and architectural professionals to deliver innovative solutions that enhance your operational reliability and e ciency.

Our success is de ned by yours. We stand on our core pillars of Pledge, Process, and People, ensuring exceptional project delivery every time. With industry-leading expertise from our employee-owners in nationwide local o ces, we exceed expectations and provide unparalleled long-term client support.

Receive Superior Engineered Solutions

SYSTEM INTEGRATION

Automation & Control Systems

Manufacturing Execution Systems

Industrial Networks

Cloud IT/OT Applications

Cybersecurity

EQUIPMENT

& SYSTEMS

Modular Integrated Control Enclosures

T&D Substation Relay Panels

Control Panels

Packaging Solutions

Rotating Equipment Control

PROFESSIONAL SERVICES

Electrical Engineering

Mechanical & Process

Civil & Structural

Architecture

Electrical Test & Commissioning

We Provide Local Client Services, Nationwide, Since 1981

Data

Semiconductor

Discrete Manufacturing

Building Management/Campus

System

Falon Simmons, Vice President fsimmons@adaptiveresources.com

McKinney, TX

Telephone: (469) 270-5503 sales@adaptiveresources.com www.adaptiveresources.com

Primary Industries

• Food & Beverage

• Robotic Material Handling

• Data Centers

• Consumer Products

• Building Materials

Other Office Locations

• Calgary, Canada

• Guadalajara, Mexico

• London, UK

• San Antonio, TX

• Bakersfield, CA

• Chicago, IL

+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.

Adaptive

RELIABLE SOLUTIONS. REMARKABLE PEOPLE

Adaptive Resources partners with companies to improve productivity, delivering measurable ROI in months with control panels, robotics, vision systems, controls and predictive software.

Our clients consolidate vendors into one accountable partner, able to solve urgent issues and scale to long-term modernization solutions. We work alongside you – moving fast, automating for performance, and remaining embedded in your plants – year after year.

Core competencies

• Advanced Process Control Software

• MES/SCADA/HMI/PLC/Sensors

• Robot, Cobot and Mobile

• Machine Vision & Traceability

• Panel Fabrication UL508A, UL698A

Strategic Partnerships

• Rockwell

• Siemens

• Omron

• Beckhoff

• Ignition

• Aveva

• Fanuc

• ABB

• Batch Systems

• CNC, Weld & Fabrication

• Process Control Consulting

• Thermal Processing

• Design Service

• Universal Robots

• Staubli

• Doosan

• Epson

• Festo

• Cognex

• Keyence

• Zebra

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

ANDRITZ

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.

Profile at www.cfemedia.com/systemintegrator/ANDRITZ

System Integrator Corporate Close-Ups

Gerry Gallo

Hialeah, FL 33016

Telephone: 305) 805-3700

Fax: 305-818-5976

https://cct-inc.com

Primary Industries

• Pumping Systems

• Baggage & Handling

• Industrial Automation

• Oil & Gas

• Power Generation

Other Office Locations

• Central and South America

CUSTOM CONTROLS TECHNOLOGY, INC.

WE ARE PRESENTING OUR NEW PRODUCT A SUBMERSIBLE ENCLOSED CONTROL PANEL FOR PUMP STATIONS AKA LIFT STATIONS.

Fully energized and functioning. This Submersible Control Panel is patented and UL Verified for No water ingress after 30 days, 12.625" above the enclosure for the CK474 model and 13"inches above the enclosure for the W8404 Model. By taking into account the following, 24" slab + 16" above the slab mounted on feet or on a Rack, the best scenario CK474 at 58" high, + 12.65" UL requirement equal 110.625" or 9.2ft). UL verification for this product is V986660 for No Water Ingress after 30 days, giving you more confidence when installing this control panel. This is the perfect solution for flood prone areas. Although this panel is not intended to work indefinitely under water, it is designed to have a resilience to flood conditions. CCT recently has tested the panel for recertification for 25 days and then continued under UL verification process and additional 30 days, under water. Which yield a complete success. Seventeen of our customized enclosure have been installed at City of Coral Gables, FL where flooding can occur during major storms.

Currently we have completed an order for LEE County Utilities for 99 units, replacing the recent devastation that occurred over more than 3 years ago.

Having the water pump control system working during the heavy rain fall is critical to minimizing the flooding. Our application can keep the system dry and intact during the catastrophic situations, protecting valuable assets and a quicker recovery for the municipality.

CCT is a UL 508A, UL 698A and pending UL 1741 certified panel shop and proud supporter of the Buy American Act. Please call or email us if you have any questions. Implementing New technology with 100% of Customer’s satisfaction. We are here to Serve You!

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

ECS Solutions

BATCH AUTOMATION EXPERTS FOR YOUR MANUFACTURING ECOSYSTEM

ECS Solutions, a Magnum Systems brand, specializes in optimizing batch manufacturing with innovative, efficient, and reliable control systems. We help manufacturers streamline operations, reduce costs, and increase production.

Why ECS Solutions?

(812) 479-5170

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

Primary Industries

• Chemicals

• Beverages & Distilleries

• Food & Bakeries

• Life Sciences

• Metals

• Water & Wastewater

Office Locations

• Atlanta, GA

• Bowling Green, KY

• Hattiesburg, MS

• Henderson, KY

• Joplin, MO

• Knoxville, TN

• Lenexa, KS

• Lexington, KY

• Parsons, KS

• Phoenix, AZ

• Raleigh, NC

• Venice, FL

International:

• Colombia

• Trusted Expertise: Over 45 years in batch operations and controls

• Custom Solutions: We analyze, design, and support tailored control systems

• End-to-End Support: One team manages everything—start to finish

• Data-Driven Decisions: Our systems deliver accurate data for quick, informed choices

How Do You Benefit?

• Process Automation: Streamline production and increase efficiency

• Production Control: Enhance operational oversight and management

• Performance Measurement: Track and improve yields and output

• Compliance: Simplify meeting regulatory standards

• Inventory Management: Optimize stock levels and reduce waste

• ERP Integration: Connect systems seamlessly for better data flow

Our Capabilities

• Batch Manufacturing

• FactoryTalk Batch

• Sepasoft MES

• PlantPAX

• Control Panel Design & Build

• Packaging Integration & Analytics

• Ignition by Inductive Automation

• Ignition & Sepasoft Batch

• Bi-Lingual Automation & Control Solutions

Contact ECS Solutions to improve your batch manufacturing with control systems that ensure consistent, high-quality results.

System Integrator Corporate Close-Ups

Kimberly Pelkey

Wilson, NC

Telephone: (252) 237-3399

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

Primary Industries

• Automotive

• Chemical Film & Plastics

• Consumer Goods

• Energy & Utilities

• Food & Beverage

• Life Science • Metals & Mining • Nonwoven & Fibers • Semiconductor

& Paper

Other Office Locations

• Cedar Point, NC

• Garner, NC

• Lucama, NC

Malisko, Inc. malisko.com info@malisko.com (314) 621-2921 St. Louis, MO

Primary Industries

• Food & Beverage

• Dairy

• Consumer Packaged Goods

• Life Sciences

• Metal, Mining, & Cement

Other Office Locations

• Denver, CO

• Eau Claire, WI

Industrial Automated Systems

IAS IS YOUR TRUSTED PARTNER IN PROJECT MANAGEMENT, CONTINUOUS IMPROVEMENT, AND AUTOMATION ENGINEERING

Manufacturing Automation Solutions & Services

• PAC

Project Management, Embedded Resources & Staff Augmentation • Owner’s Representative

Qualification Testing

Continuous Improvement

Performance Tracking and Reporting

Reporting and Analytics

Partners / Affiliates

Rockwell Automation Silver System Integrator

IAS is an independent, turnkey automation provider improving quality and productivity for our global customers through innovative engineering and technology. A strategic partner for project management, system integration, and continuous improvement. Full Profile at www.cfemedia.com/systemintegrator/industrialautomatedsystems

Turnkey Projects

Qualification Testing

Malisko

CONNECTING PEOPLE, PROCESS AND TECHNOLOGY.

For over 30 years, we have connected people, process, and technology to improve manufacturing productivity and efficiency. Our team of engineers, designers, programmers, automation, and network & security specialists listen to understand your needs and develop personalized solutions. When you work with us, you’re not just investing in process automation. You’re investing in a business partnership with a group of dedicated, multi-disciplined efficiency professionals.

Malisko offers a full suite of services that work well independently or together.

Our foundation in Industrial Control Systems brings practical OT experience and perspectives to Digital Transformation and Industry 4.0 initiatives.

IT/OT Convergence

We have the unique ability to bridge the gap between IT and OT with our Industrial Network, Security, and Information Specialists. Our specialists have instant credibility with both sides based on practical experience.

Plant Floor Control & Process Automation Solutions

We have nearly three decades helping manufacturers streamline their process by integrating various technologies and components to enhance efficiency, productivity, and data accuracy on the plant floor.

Manufacturing Intelligence

We help manufacturers harness the power of manufacturing intelligence by collecting, analyzing, and utilizing data to optimize processes, reduce costs, and improve overall performance in a customized and sustainable manner.

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

System Integrator Corporate Close-Ups

Matrix Technologies

“GO BEYOND AUTOMATION – YOUR SINGLE SOURCE SOLUTION”

Matrix Technologies, Inc. is your single-source partner for Engineering, Construction, Automation, and Information project needs. 85% of our projects are repeat engagements successfully delivered to our satisfied clients. Kevin Overmyer, MBA, Director of Client Solutions & Success Maumee, OH matrix@matrixti.com 419-897-5630 www.matrixti.com

Markets We Know

• Food & Beverage

• Feed/Grains/Oilseed

• Wine & Spirits

• Life Sciences

• Consumer Products

• Specialty Chemical

• Oil/Gas/Refining

• Metals

Office Locations

• Atlanta, GA

• Cincinnati, OH

• Denver, CO

• Indianapolis, IN

• Kansas City, KS

• Maumee, OH

• Minneapolis, MN

• Manufacturing Automation

– Process Controls & Automation

– Batch Systems

– Continuous Systems

– Filling and Packaging Systems

– Utility Systems Automation

– Retrofit and Greenfield Installations

– Building Automation

– I/0 Checkout, Startup, and Commissioning

• Manufacturing System Infrastructure

– Industrial Control System (ICS) Network Assessments

– Industrial Control System (ICS) Security & Reliability

– Server Infrastructure and Virtualization

– Cybersecurity Assessments

– Network Design and Configuration

– iDMZ – Industrialized Demilitarized Zone

• Manufacturing Intelligence

– Manufacturing Execution Systems (MES)

– Manufacturing Operations Management

– Industrial Internet of Things (IioT) in Manufacturing

– Digital Transformation and Artificial Intelligence

• Control System Electrical Design

– Control Network Design

– Control Panel Design and Fabrication

– PLC, Drives, HMI, Operator Stations

– Schematics and Safety Circuits

– UPS Protection

– Motor Control Centers

• Regulatory Compliance

– Data Integrity

–21 CFR Part 11

– System Validation

– cGMP and/or cGXP

• Service Group

–24/7 Support of Automation Systems

– Multiple contract arrangements available

– On call and contract-based support

• Multi-Discipline Engineering

• Capital Project Planning

• Engineer Procure Construct (EPC) Project Execution

• Project Management

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

Pacific Blue Engineering

Pacific Blue Engineering info@pacificblueengineering.com www.pacificblueengineering.com (657) 201-8603

Primary Industries

• Food and Beverage

• Entertainment

• Transportation

• Life Sciences

• Manufacturing

Office Locations

• Long Beach, CA

• Orange, CA

• Orlando, FL

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

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 1,400 projects.

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

Certifications & Associations

• TUV SUD and TUV Rheinland Functional Safety Engineers

• UL 508A Panel Shop

• CSIA member

• ISNetworld / Avetta

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