Equipment Programming & Industrial Automation

Expert PLC programming, HMI and SCADA development, network integration, machine retrofitting, controls upgrades & custom automation solutions.

Smart Automation. Seamless Integration. Reliable Results.

At PolSys, we specialize in delivering optimal industrial automation services and solutions to increase productivity, reduce downtime, and help “future-proof” your operations.

Because of our combined expertise in automation engineering, PLC programming, HMI/SCADA integration, and controls design, we are a trusted partner to many Fortune 100 manufacturers in different market sectors—including automotive, food & beverage, pharmaceuticals, energy, and more. From concept to commissioning, you can trust our team to design and deliver an optimal turnkey solution tailored to your facility’s unique needs.

Automation expert working on equipment programming

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Core Automation Services

Our team is fully trained and equipped to troubleshoot, repair, program/re-program, and upgrade all types of automated equipment.

PLC Programming

Our certified engineers design, develop, and optimize PLC logic for all major platforms—including Allen-Bradley, Siemens, Omron, Schneider Electric, and more. Whether you’re upgrading legacy systems or building from the ground up, we deliver clean, efficient, and scalable code to maximize your system’s performance.

On-site Hardware Programming

We provide responsive, nationwide on-site programming on PLCs, HMIs, SCADA, drives, motors, sensors, and actuators. We can also calibrate industrial sensors (e.g., temperature, pressure, flow, etc.) and actuators (e.g., valves, motors, etc.) and service Variable Frequency Drives (VFDs), servo drives, and soft starters.

HMI & SCADA Development

We create intuitive, operator-friendly Human-Machine Interface (HMI) and SCADA systems that give your team real-time visibility and control over production processes. Custom graphics, alarm handling, trending, and remote access are built to suit your exact workflow.

Software and Configuration Services (On site & Off-site)

We provide Control Logic Recovery and Reinstallation for PLC crashes; Firmware Updates for PLCs, HMIs, and other devices; Communication Network Troubleshooting (e.g., ethernet/IP, Modbus, Profibus, etc.) and Repair; and SCADA & HMI Troubleshooting and Repair – including fixing software issues, corrupted files or misconfigurations in control interfaces.

Industrial Network Integration

From EtherNet/IP and Modbus to Profinet and Profibus, we design and implement robust industrial communication networks that ensure seamless interoperability between machines, systems, and enterprise software.

Machine Retrofitting & Control Upgrades

Modernize your aging equipment with control panel redesigns, PLC conversions, and hardware/software upgrades. Extend the life of your machinery while meeting current safety and performance standards. Learn more about our control system upgrades.

Control Panel Redesign, Engineering & Fabrication

Our turnkey Panel Redesign, Engineering, and Fabrication services enhance performance, safety, and compliance. From modernizing outdated systems to custom-engineering new solutions, our team delivers precision-built panels tailored to your needs.

Custom Automation Solutions

From concept to commissioning, we can handle everything—control system architecture, panel building, software development, I/O testing, FAT, SAT, and on-site startup.

Cybersecurity-related Services

Help protect your automated systems from cyberthreats with control system hardening (patching vulnerabilities in legacy ICS systems), network segmentation and firewall setup services. Restore services after an attack on control infrastructure with our incident recovery services.

Why Choose PolSys for Industrial Automation?

PolSys expert working on a control system upgrade

Cross-Platform Expertise
We’re brand-agnostic and work with Rockwell, Siemens, Beckhoff, Mitsubishi, and more—ensuring we can integrate with your existing systems or recommend the best fit for your goals.
Turnkey Delivery
From design to deployment, we handle every stage of the automation lifecycle so you don’t have to manage multiple vendors.
Uptime-Focused Approach
We understand the cost of downtime. That’s why our solutions are built with reliability, maintainability, and diagnostics in mind.
Compliance & Safety First
All designs meet applicable UL508A, CE, NFPA 70/79, and ISO/IEC standards, ensuring your systems are safe, compliant, and audit-ready.

Control Service Upgrades

We can make honest, unbiased recommendations to improve aging systems and/or offer a free quote on a control system upgrade. If your control system is becoming obsolete, we can recommend an optimal replacement. Our experience includes on-site modification of control panels as well as custom-designed/build replacement systems.

Related Controls Case Studies

Process Heating Article: Do You Have Control Issues?

This expert article — written by us and featured in Process Heating magazine — highlights five common but often overlooked issues with industrial control systems on air pollution control equipment. Drawing from real-world experience that includes a case study, it explains why these “hidden” problems can lead to costly downtime or compliance risks—and why an upgrade may be the smartest next step.

Service: Control System Upgrade
Industry: Manufacturing
System: Industrial Controls RTO

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Service Agreements: “Insure” your System Against Unplanned Downtime

For maximum system reliability and production uptime, choose a Rapid Response Service Agreement. Plans include inspections, technical support, and emergency call-outs with guaranteed response times. If you’re operating at or near capacity, these site-specific agreements can pay for themselves many times over in increased system reliability, safety & compliance.

Service Agreement Features Contact Us

How to Troubleshoot Your PLC: 10 Pro Tips

Mar 27, 2025 Control Systems

Unfortunately, troubleshooting a PLC that won’t communicate effectively with other devices can be challenging, time-consuming, and costly. So where should you start and what steps should you follow?

Control Systems: Small Issues That Cause Big Problems

Sep 27, 2024 Control Systems

Even "minor" control system issues—like clogged filters, loose connections, etc.—can shut down production. Our Sr. Controls Engineer describes five “easy-to-miss issues” that he often finds.

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24/7 Nationwide Service

We provide responsive, nationwide coverage for our services, including the metropolitan areas of Houston, Dallas, Chicago, Detroit, Milwaukee, Minneapolis, and The Northeast.