This project involved the integration of a new electrocoagulation treatment system as part of a wastewater process upgrade to improve environmental compliance.
We were responsible for the full design and implementation of the local PLC control for the electrocoagulation unit. The control system managed the reactor, mixers, and cleaning systems, with over 50 I/O points including flow meters, motorised valves, mixers, ultrasonic cleaners, and instrumentation.
A dedicated control panel was supplied complete with a new PLC and interface. The system was networked with two other new site PLCs, and key data was shared for coordinated operation and site-wide telemetry.
A bespoke PLC strategy was developed to automate the dosing process based on flow conditions, manage flushing routines, and calculate electrode wear in real-time. Manual and automatic modes were provided through a local operator interface, along with alarm handling and remote monitoring capability.
This solution delivered a fully automated, robust control platform for the new treatment process while maintaining flexibility for operators.
Project: Diagnosed and rectified control faults on a snack packaging line causing frequent downtime.
What We Did:
Rewrote PLC step sequencing with timing improvements
Added I/O diagnostics and replaced faulty sensors
Implemented interlocked reject routines to reduce jams
Impact:
Line uptime increased by 35% and fault rate was reduced to nearly zero within 2 weeks.
Project: Automated dosing system for ferric, sodium hydroxide, PACL, and poly at a treatment works.
What We Did:
Developed PLC logic for individual and combined dosing lines Installed flow-based dosing with level fail-safes and interlocks Built touchscreen HMI for intuitive operator interaction
Impact:
Reduced chemical overuse, improved dosing accuracy, and enabled fast changeovers without operator intervention.
We are a team of expert software and automation engineers with a passion for delivering exceptional industrial control solutions.
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NAPIT Certified | PLC & HMI Specialists
