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OUR PROJECTS

A selection of completed automation and control engineering projects across a range of industries and processes.

System Concepts PLUS has successfully delivered automation solutions for manufacturers across the Southeast. Below is a representative sample of our project work — from single-machine upgrades to full system integrations.

Manufacturing / Production

AC to DC Conversion

Drive Upgrades, Motor Replacement, PLC Integration

Completed numerous DC-to-AC conversion projects, upgrading entire production lines by replacing DC motors and drives with modern AC motors and drives. These upgrades improve operational efficiency, increase system reliability, reduce maintenance requirements, and keep production equipment current with modern industrial automation technology.

DC to AC motor & drive replacement
Full production line upgrades
Improved operational efficiency
Reduced maintenance requirements

Recycling / Plastics

Electrostatic Seperator Panel Update

Controls Overhaul, PLC Upgrade, HMI Modernization

Performed a complete controls overhaul on an electrostatic plastic sorting machine used in the recycling industry. Rebuilt the entire control panel and upgraded the PLC and HMIs to modern technology, improving system functionality, reliability, and maintainability.

Full control panel rebuild
PLC & HMI modernization
Electrostatic sorting machine
Improved system reliability

Leak Testing / Quality Control

Hydro Tester

Custom Panel Design, Control System Build

Designed and built custom control panels for specialized leak-testing equipment used to verify component integrity. The machines test for air leaks by pressurizing components while submerged in a water bath, allowing leaks to be identified through escaping air bubbles.

Custom control panel design & build
Pressurized air leak detection
Water bath submersion testing
Component integrity verification

Adhesives / Packaging

Glue Filler

Controls Design, PLC Programming, Weight-Based Automation

Designed and implemented the controls for a custom adhesive-filling production line. The system automatically fills buckets to a specified product weight, stops dispensing when the target weight is reached, and advances to the next bucket for a consistent and efficient filling process.

Automated weight-based fill control
Auto-advance to next container
Consistent & repeatable process
Custom production line controls

Plastics / Extrusion

Extrusion Line Upgrade

Electrical Design, Drive Integration, CAD Documentation

Completely overhauled a multi-zone extrusion line with a new Allen-Bradley PLC, upgraded controls, and modernized automation systems. Reprogrammed zone-to-zone speed coordination to improve process control, increase product consistency, reduce scrap rates, and improve overall line reliability.

Yaskawa VFD integration
Multi-zone speed coordination
CAD as-built drawings
Startup & commissioning

Water / Utilities

Pump Station Monitoring & Control

PLC Programming, SCADA Integration, Panel Fabrication

Designed and built a remote pump station control panel with PLC-based monitoring, alarm management, and SCADA integration for centralized oversight of multiple pump stations.

Remote monitoring via SCADA
Alarm management system
Custom control panel
Cellular communications

Converting / Paper

Winder Control System Modernization

PLC Programming, Tension Control, HMI Design

Modernized the control system on a surface winder, implementing closed-loop tension control and diameter calculation. The new HMI provided operators with real-time tension feedback and recipe management.

Closed-loop tension control
Diameter calculation logic
Recipe management HMI
Allen Bradley PLC

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