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RTO Control System Upgrades for Fortune 100 Auto Manufacturer

A global Fortune 100 automotive manufacturer faced major operational challenges due to outdated PLC and HMI hardware in their 4 Regenerative Thermal Oxidizers (RTOs).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.

Control panel

Control System Upgrade Ends RTO Shutdowns for Chemical Plant

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.

Small regenerative thermal oxidizer on-site

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.

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