Process line re-control

The line was controlled by relay logic that had been modified so many times the drawings no longer matched the panel. Every fault was an investigation rather than a diagnosis.

We rebuilt the control system around a PLC and HMI, keeping the existing motor starters and field wiring wherever they tested sound. The logic was written from the machine's actual required sequence, observed and recorded on site, then reviewed with the operators before anything was switched over.

Commissioning ran in phases across planned shutdowns, with a documented rollback at each stage. When the line restarted it came back with a clear fault log, alarm history and a set of drawings that finally described the machine.