A well-automated production line makes more, stops less and delivers quality that does not depend on the shift. We take care of the whole chain: from the sensor that measures to the KPI that management sees.
Production line automation
We program the logic that coordinates a complete line: conveyors, machines, robots and manual stations. We work with the IEC 61131-3 languages (structured text, ladder, function blocks) and document the code so your maintenance team can understand and modify it.
- PLC and HMI programming
- Motion control: servos, synchronised axes and electronic cams
- Robot and robotic cell integration
- Communication between machines from different vendors
- Simulation testing (FAT) before going on site
- On-site commissioning (SAT)
- IEC 61131-3
- PLC
- HMI
- Motion control
- Robotics
- FAT / SAT
Machine retrofit and modernisation
Many machines have perfectly good mechanics and obsolete controls: no spare parts, no documentation, no way to connect them. We replace the PLC and the operator interface, migrate or rewrite the program and connect the machine to the rest of the plant, with minimal downtime.
- Migration of discontinued PLCs
- Re-engineering of undocumented programs
- New operator screens and panels
- Connection to MES, ERP and data systems
- Downtime planned together with production
- Retrofit
- PLC migration
- Obsolescence
Automatic process control
We design and tune the control loops that keep every variable at its setpoint: the temperature of a kiln, the pressure of a circuit, the flow of a dosing system or the level of a tank. A well-tuned loop reduces variability, energy consumption and off-spec product.
- PID loops and tuning
- Cascade, feedforward and ratio control
- Batch control and recipes to ISA-88
- Start-up, shutdown and product changeover sequences
- Control of kilns, dryers, reactors and mixers
- PID
- Cascade
- ISA-88
- Recipes
- Batch control
SCADA, HMI and alarm management
Operators need to see at a glance what is happening and what to do. We design clear screens, useful historians and alarms that only fire when action is needed, so nobody learns to ignore them.
- SCADA and plant supervision systems
- HMI screens designed around the operator’s task
- Process historians and trends
- Alarm rationalisation to ISA-18.2
- Secure remote access for support
- SCADA
- HMI
- ISA-18.2
- Historians
Industrial measurement and instrumentation
Without reliable measurement there is no control. We select the right instrument for each variable and environment, install it, calibrate it and bring its signal into the control system.
- Temperature, pressure, flow, level, humidity and viscosity
- Process analysers
- Instrument calibration and verification
- 4-20 mA, HART and IO-Link signals
- Fieldbuses: Profinet, EtherCAT and Modbus TCP
- Data acquisition for tests and validations
- 4-20 mA
- HART
- IO-Link
- Profinet
- EtherCAT
- Modbus TCP
- Calibration
Industrial data analytics and Industry 4.0
The data your machines already produce can tell you where production is being lost. We capture it, organise it and turn it into KPIs and models that support decisions: which machine stops most, which shift scraps most and which component is about to fail.
- Data capture with OPC UA and MQTT
- OEE: availability, performance and quality
- Statistical process control (SPC)
- Anomaly detection and predictive maintenance
- Production, quality and maintenance dashboards
- MES and ERP integration
- OPC UA
- MQTT
- OEE
- SPC
- Predictive maintenance
- Industry 4.0
Industries
We work in the process industry and inline manufacturing, with particular experience in the Castellón ceramic cluster.
- Ceramics and porcelain. Presses, dryers and kilns.
- Food and beverage. Dosing, batches and traceability.
- Chemicals and plastics. Reactors, mixing and extrusion.
- Packaging and board. Packing and palletising lines.
- Textile. Dyeing and finishing.
- Wood and décor. Panels, lacquering and finishing.