Gallery

A sampling of our work

Fresh Produce

Twin Frick Ice Plant

New York

Project Highlights

  • New control system for greenfield ice production facility with two Frick 36 TIMs with two Vilter 458XL in a recirculating configuration.
  • Redundancy controls to allow machine to continue operation in a reduced state if single compressor or TIM has individual fault.
  • HMI allowing user customization of cycle set points and easy facilitation of regular service and maintenance procedures.
  • Secure remote access for troubleshooting, program updates and remote viewing of process by end user.
  • Notifications of faults and daily statistics.
  • Full control of recirc skid with pump failover and lead switching.

Twin Vogt Ice Plant

Virginia

Project Highlights

  • Provide new control system for ice production facility with two Vogt P34A tube-ice machines operating in tandem with two Mycoms.
  • HMI allowing user customization of cycle set points and easy facilitation of regular service and maintenance procedures.
  • Secure remote access for troubleshooting, program updates and remote viewing of process by end user.
  • Notifications configured for unexpected machine shutdowns to allow for fast response and increased uptime.
  • Automated shutdown to observe peak electric billing hours.

Slush Ice Clamshell

Georgia

Project Highlights

  • Provide updated control system for air-operated Polar Ice clamshell.
  • HMI allowing user customization of cycle set points.
  • Secure remote access for troubleshooting, program updates and remote viewing of process by end user.
  • Notifications configured for reporting of daily production data.
  • VFD For precise control of makeup ice feed rate.
  • Wireless remote control of icing process and makeup ice for single person operation from forklift.

Hydrocooler

Virginia

Project Highlights

  • Provide control system for hydrocooler and nearby coolers.
  • HMI allowing user customization of zone settings.
  • Secure remote access for troubleshooting, program updates and remote viewing of process by end user.
  • Notifications configured for high temp allowing fast response and less damage to product.
  • Configured for future ability to automate chemistry with reporting for food safety.

Frick Ice Plant

Georgia

Project Highlights

  • Retrofit control system for ice production facility consisting of Frick 50-ton mini-tube ice machine, Vilter compressor and Evapco condensor.
  • HMI allowing user customization of cycle set points, compressor health monitoring, Evapco set points and cycle data.
  • Secure remote access for troubleshooting, program updates and remote viewing of process by end user.
  • Notifications configured for unexpected machine shutdowns and daily production data.
  • Flowmeter for infeed water monitoring to estimate ice production.
  • Automated shutdown to observe peak electric billing hours.

Turbo Ice Plant

Georgia

Project Highlights

  • Provide new control system for mobile ice production unit consisting of 40-ton Turbo fractured ice machine with Vilter compressor & Evapco.
  • HMI allowing user customization of cycle set points and easy facilitation of regular service and maintenance procedures.
  • Secure remote access for troubleshooting, program updates and remote viewing of process by end user.
  • Notifications configured for unexpected machine shutdowns to allow for fast response and increased uptime.
  • Automated harvest advance to increase production in variable weather.

Slush Ice Clamshell

Virginia

Project Highlights

  • Create control system for hydraulically operated clamshell ice injector.
  • HMI allowing user customization of cycle set points and logging of cycle data.
  • Secure remote access for troubleshooting, program updates and remote viewing of process by end user.
  • Notifications configured for reporting of daily cycle data.
  • Wireless, battery-less remote control for start/advance/stop sequence.
  • Full manual over-ride.

Frick Ice Plant

Georgia

Project Highlights

  • Provide new control system for ice production facility consisting of Frick 50-ton mini-tube ice machines, Vilter compressor and Evapco.
  • HMI allowing user customization of cycle set points and easy facilitation of regular service and maintenance procedures.
  • Secure remote access for troubleshooting, program updates and remote viewing of process by end user.
  • Notifications configured for unexpected machine shutdowns to allow for fast response and increased uptime.
  • Automated harvest for increased production in variable conditions.

Dairy

Chlorine Dioxide

Wisconsin

Project Highlights

  • Integrate Dioxide Pacific electro-chemical chlorine dioxide generator into central chlorine dioxide supply for farm.
  • Dose animal drinking water at low rate with Promilent pump.
  • Design and build dip mixing setup to create pre and post dip products using chlorine dioxide and additional additives as needed.
  • HMI for ease of use, calibrations, and recipe adjustments.
  • Notifications for low product levels and system faults.
  • Integration into Bitmasked Dashboard for easy data access.

Cow Cooling

Wisconsin

Project Highlights

  • Integrate existing fans and soakers into automated control system.
  • Control all functions based on Temp Humidity Index.
  • Continuously variable soaker settings based on THI, no stages.
  • Remote mounted HMI for ease of use and configuration.
  • Ready for integration into future cooling additions.

Milk Cooling

Various

Project Highlights

  • Variable plate cooler water flow control system.
  • Uses positioner valve to modulate plate cooler well water flow rate.
  • Valve position paces milk flow with gain and min flow adjusted by user.
  • Compact HMI for ease of setup and adjustments.
  • Additional scaling compensated for based on collection tank level.
  • Provisions for temperature or VFD speed based flow pacing.
  • Lowers milk temp while reducing water usage.

Grain

Grain Drying/Mill

Wisconsin

Project Highlights

  • Design control system for greenfield grain processing site.
  • Staged construction each year, design accommodates future expansions and feature additions.
  • Interface dryer control system for remote monitoring and control. 
  • Interlocking and cleanout times for all grain movements.
  • Automated grain transfer operations (from source to destination)
  • Automated operation of IFA Mill.
  • Radar levels for all bins.

Grain Mill

Wisconsin

Project Highlights

  • Design control system to integrate into existing processing site.
  • Interface with existing VFDs for motors and distributor via Ethernet.
  • Interlocking and cleanout times for all grain movements.
  • Fully automated milling with automated restarting when bins low, automated cleanout and transfer to next bin when full and automated shutdowns when all finished bins full or supply storage low.
  • Remote monitoring and notifications of any faults.
  • Radar levels for all bins.

Grain System

Oklahoma

Project Highlights

  • Design control system for existing grain handling/storage site.
  • Staged construction each year, design accommodates future expansions and feature additions.
  • Interface with existing dryer control system for remote monitoring and control. Integrate with Bitmasked Dashboard for one-man operation.
  • Interlocking and cleanout times for all grain movements.
  • Interface with VFDs for air handling and cleaner.
  • Establish communication with scale for inbound/outbound tracking.
  • Radar level sensing for automated overhead filling.

Grain System

Wisconsin

Project Highlights

  • Design control system for greenfield grain handling/storage site.
  • Interface dryer control system for remote monitoring and control. 
  • Interlocking and cleanout times for all grain movements.
  • Radar level sensing for all bins, automated OH filling and shutdowns. 
  • Programmable stack-light for display of wet bin and OH levels.

Grain System

Wisconsin

Project Highlights

  • Design control system for new/retrofit grain facility.
  • Interface dryer control system for remote monitoring and control. 
  • Interlocking and cleanout times for all grain movements.
  • Radar level sensing for storage bins, automated shutdowns.
  • Position sensing for manual distributor controls.
  • Automated filling of overheads.

Mobile Equipment

Hay Stacker

Texas

Project Highlights

  • Design control system for hydraulic, towed hay stacker.
  • Joystick user control and HMI mounted in tractor cab. 
  • Power and ethernet communications between tractor and unit.
  • Maintain precise control over pusher chain using encoder and PWM.
  • Create automated pick routine and interlocking.
  • Develop new control system to replace prototype system for production machines using CoDeSys machine controllers and HMI. 
  • Design wiring harness for production machines.

Industrial

Milling/Bagging

Wisconsin

Project Highlights

  • Design control system for automated filling of totes.
  • Designed with consideration for integration into larger system to control end to end process.
  • Communication to four scale systems for weight readings.
  • Compact HMI for operator adjustment of set points.
  • Simple unattended filling routine requires single button press from operator. Fills totes with 99.5%+ accuracy.
  • Multi-state LED indicators for visual reference of station state.

Cloud Monitoring

Various

Project Highlights

  • Monitor various analog and discrete signals for cloud logging.
  • Design compact system to connect to existing internet connections.
  • Send data to dashboard at predetermined intervals or key events.
  • Provisions for two-way control provided if needed.
  • Expandable platform allows for easy additions of extra points.
  • PLC facilitates easy automation, if desired in addition to the reporting.

Packaging

Compression Baling

Wisconsin

Project Highlights

  • Commission Premier compression bagging machine.
  • Design robotic palletizing cell for future installation.
  • Provide consulting on future integrations.