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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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Grain
Grain Dryer
Wisconsin
Project Highlights
- Design control system for greenfield grain processing 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.
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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.
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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.
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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.
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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.
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Packaging
Compression Baling
Wisconsin
Project Highlights
- Commission Premier compression bagging machine.
- Design robotic palletizing cell for future installation.
- Provide consulting on future integrations.
