Client Challenge
A specialty materials manufacturing facility relied on an aging control system to operate a large, motor-driven production process. Over time, the existing control infrastructure became increasingly difficult to maintain, limiting the facility’s ability to support reliable operations and future expansion.
The system coordinated dozens of motors across multiple control panels responsible for key production equipment. As equipment aged and production demands increased, the facility needed a more modern automation platform capable of improving reliability, enhancing monitoring capabilities, and supporting long-term growth.
In addition to modernizing the control architecture, the customer required a solution that could be implemented with minimal disruption to operations. Any upgrades to the system had to carefully balance the need for improved functionality with the realities of maintaining ongoing production.
The facility partnered with DSI Innovations to evaluate the existing system and develop a strategy for upgrading the control infrastructure while maintaining operational continuity.
Our Solution
DSI Innovations approached the project through a phased automation strategy designed to modernize the facility’s control systems while minimizing production downtime.
The initial phase involved evaluating the existing control environment and identifying opportunities to improve system architecture and reliability. Based on this assessment, DSI engineered a comprehensive controls upgrade centered around a modern PLC platform capable of coordinating a large motor-driven process system.
The project included the reworking of two major motor control panels supporting critical production equipment. DSI upgraded the control hardware, integrated variable frequency drives and starters, and implemented new networking and automation components to support improved system coordination.
Across the upgraded panels, the new control system was designed to manage approximately 92 motors operating throughout the process system. DSI developed the PLC programming and human-machine interface (HMI) configuration necessary to coordinate motor operations, provide real-time system visibility, and improve troubleshooting capabilities for plant operators.
Following the primary automation upgrade, DSI also engineered and fabricated an additional motor control panel to support expanded equipment requirements. This expansion project integrated seamlessly into the upgraded PLC architecture, demonstrating the scalability of the new automation platform.
DSI provided full lifecycle project support, including engineering design, panel fabrication, PLC programming, system commissioning, and operator training.
The Results
The completed automation upgrade significantly improved the reliability and scalability of the facility’s motor control infrastructure.
By modernizing the PLC architecture and integrating updated control hardware, the facility gained improved coordination across a complex motor-driven production process. The system now manages 92 motors through a combination of starters and variable frequency drives, allowing for more efficient operation and improved process control.
Operators now benefit from improved system visibility and monitoring capabilities, enabling faster troubleshooting and more informed operational decisions. The upgraded control platform also positions the facility for future expansion, allowing additional equipment to be integrated into the automation system as production needs evolve.
Perhaps most importantly, the phased implementation strategy allowed the facility to modernize critical automation infrastructure while minimizing disruption to ongoing production.
Through careful engineering and collaboration with the customer, DSI delivered a scalable automation solution that improved operational reliability while preparing the facility for continued growth.
