A control system upgrade can transform your entire operation, boosting reliability, safety, cybersecurity, and uptime across your plant. Whether you’re upgrading a single line or modernizing an entire facility, our controls experts can help you build a smarter control architecture with cost-effective, robust solutions tailored to your needs.
Control panel prior to upgrade.
Upgraded control panel. Our unbiased solutions are designed for modularity and seamless integration to minimize disruption and maximize ROI.
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The right modern control system can resolve these system constraints efficiently and cost-effectively.
Industrial control system design is vital to the reliability, functionality, and efficiency of thermal oxidizers, scrubbers, and other process equipment. If you’re operating with outdated controls, you’re operating at a major disadvantage. Benefits to upgrading your legacy control system include:
Our team combines advanced expertise in industrial control systems with broad mechanical field experience. We’re a single-source service partner unaffiliated with any certain major manufacturer or brand, so we’re capable of understanding the “big picture” at your facility and can offer you the optimal solution for your equipment and needs.
Many existing system setups can be retrofitted or integrated into new control platforms with minimal downtime and disruption. Through planning, protocol alignment, and phased commissioning, you can continue operations without interruption or with minimal downtime. Our solutions:
For over 30 years, we’ve provided automation solutions designed for air pollution control. No one has more experience with control systems on Regenerative Thermal Oxidizers (RTOs), thermal oxidizers, scrubbers, and other types of emissions equipment.
Control systems for Regenerative Thermal Oxidizers (RTOs) are a special focus. An RTO’s control system oversees key operations, including poppet valve switching, temperature, retention times, and much more. If your RTO’s control system is not properly programmed – or if it has been improperly adjusted to correct for another issue – it can cause reliability, safety, and compliance issues.
A major chemical manufacturer operating 24/7 faced frequent shutdowns due to a failing legacy control system on their Regenerative Thermal Oxidizer (RTO). These disruptions led to costly permit violations and production losses. To address these critical issues, we delivered a fast, customized control system upgrade that significantly improved reliability, compliance, and overall operational efficiency.
A global Fortune 100 automotive manufacturer faced major operational challenges due to outdated PLC and HMI hardware in their 4 Regenerative Thermal Oxidizers (RTOs). These legacy systems not only risked future manufacturer support but also contributed to unplanned downtime and inefficiencies. Read how our turnkey control system upgrade delivered robust, reliable performance—minimizing downtime, improving responsiveness, and streamlining operations.
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.
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?
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.
We provide responsive, nationwide coverage for our services, including the metropolitan areas of Houston, Dallas, Chicago, Detroit, Milwaukee, Minneapolis, and The Northeast.
