Metromotion Controls writes PLC, SCADA and HMI code that follows how the process actually runs, with batch and recipe sequencing, CIP modes and tuned thermal, pressure and level loops for dairy, beverage and food manufacturers across Victoria and Australia.
Metromotion Controls provides PLC programming in Melbourne for production equipment, process areas and site-wide control rooms. Work includes SCADA and HMI programming, Ignition SCADA integration, legacy PLC migration, targeted improvements, FAT, SAT and post-start support.
Our PLC programming method focuses on modular, testable code that operators and engineers can support years after commissioning. We apply ISA-88 where sequencing or recipe logic is required, and we structure reusable function blocks for motor control, valve manifolds, analogue loops and safety interfaces. Naming conventions, alarm classes and permissive logic are defined early so each machine cell behaves consistently. We also implement diagnostic tags and historian-ready data models so SCADA and reporting layers can use reliable signals without rework.
PLC programming work moves faster when the site can provide current PLC backups, electrical drawings, network details, alarm lists, change notes and a clear description of the operating problem. We review the existing logic before touching a live system, confirm who can approve changes and define how the line will be tested before production restarts. For running food, beverage and dairy sites, this preparation is what lets PLC changes, SCADA updates and HMI fixes land inside a shutdown window rather than becoming an open-ended fault-finding exercise.
HMI and SCADA design follows ISA-101 principles and practical operator feedback from site workshops. We prioritise high-contrast graphics, clear process context, consistent navigation and alarm handling that supports fast decisions. Platforms include Ignition Perspective, FactoryTalk View SE, WinCC Unified and AVEVA System Platform. As an Ignition Gold Certified System Integrator in Melbourne, we use Ignition for plant-wide SCADA, historian, reporting and data integration where it fits the site architecture. Screens show process limits, interlock status and step progress so shift teams can diagnose faults quickly. Role-based access, audit trails and change logs support GMP and internal governance requirements.
Legacy PLC and SCADA migration is planned around production continuity. We migrate PLC-5, SLC 500, S7-300 and older SCADA nodes to modern architectures using staged conversion and test environments. Existing source code is reviewed for hidden assumptions, then rewritten with modern diagnostics and maintainable structure. FAT scripts, I/O simulation, cutover run sheets and fallback plans keep change windows controlled, with documentation and training provided after startup.
Ignition is a strong fit where a plant needs scalable operator screens, historian data, dashboards, database integration and secure browser access. Metromotion Controls designs the tag model, gateway structure and database interfaces so Ignition supports day-to-day operation as well as reporting, CMMS, OEE and continuous improvement work.
Process behaviour is built into the code from the start. We start pumps and valves under control, using VFD ramps and characterised, profiled valve closure so transfer and CIP lines do not slam shut and water hammer the pipework. Loops are tuned to their own dynamics: PI for fast flow and pressure control, full PID with anti-windup for slow thermal loops on pasteurisers, glycol, steam and hot water, and averaging control where surge tanks and levels should absorb variation rather than chase it. Prime and flush steps are sequenced so transfers stay clean and product is not diluted, and CIP loops carry their own tuning and setpoints rather than reusing production values.
Yes. Metromotion Controls provides PLC programming in Melbourne for existing production lines, brownfield upgrades, OEM equipment integration, fault recovery and legacy migration. We plan changes around site access, backups, testing evidence and production windows so the work can be commissioned with controlled risk.
Some PLC changes can be prepared, reviewed and downloaded with little or no production interruption, while others need a planned shutdown. We confirm the controller platform, process risk, available test method and rollback plan before recommending how the change should be made.
We work across Rockwell Allen-Bradley, Siemens, Omron, Schneider and mixed legacy PLC environments. We also support connected SCADA and HMI platforms including Ignition, FactoryTalk View, WinCC, Citect and AVEVA.
Standard libraries reduce defects, speed up new projects and make troubleshooting predictable. They also simplify training because electricians and engineers see the same control patterns across different machines and lines.
Yes. We can develop remotely using secured VPN and staging servers, then complete FAT and SAT with your team. This model is useful for interstate sites and allows earlier progress before site access is available.
Yes. Metromotion Controls is an Ignition Gold Certified System Integrator based in Melbourne. We deliver Ignition SCADA, Perspective, historian, database and reporting projects for manufacturing sites.
Yes. We plan legacy PLC and SCADA migrations around production continuity, source-code review, staged testing, FAT scripts, I/O simulation, cutover run sheets and fallback plans.
In many cases yes. We can redesign key screens, rationalise alarms, improve navigation and add better diagnostics while retaining your existing SCADA platform, provided the underlying infrastructure remains supported.
Automation, traceability, CIP, SCADA and production data for Australian food and beverage plants.
Controls for dairy processing, milk receival, pasteurisation, CIP and production reporting.
Batch, recipe, work order, CCP and OEE systems for pet food manufacturing environments.
Modernise legacy PLC, SCADA, HMI and control infrastructure with staged cutover planning.
Large capital project delivery across process automation, electrical engineering and commissioning.
Pet food raw materials automation covering batching, handling and production control requirements.
Planning an upgrade without losing production on a live Australian manufacturing site.
SCADA system design considerations for alarms, records, historian data and operator use.
The IEC 61131-3 languages and when each fits, maintainable code and sequence design, platform differences, commissioning and version control.
Lactalis Australia needed programming, commissioning and production support across multiple dairy sites, each with its own installed base and running production that the work had to fit around. Metromotion Controls worked across Bendigo, Echuca, Tamar Valley, Longwarry, Rowville and Lemnos, validating CIP sets step by step so cleaning sequences met hygiene requirements before lines returned to product, and carrying SCADA work in Citect consistently across the site systems. The engagement covered process upgrades, OEM installations, CIP validation and SCADA work.
McCormick is one of the world's largest spice and flavouring manufacturers, with production facilities across Australia. When the team needed to migrate a critical Clean-In-Place system to a modern, maintainable platform, Metromotion Controls delivered a full migration to Ignition SCADA with integrated database, multi-terminal operator access, and a distributed control architecture spanning the facility. CIP systems are production-critical in any flavouring or seasoning environment, and the migration was planned and executed to maintain production continuity throughout.
Chobani needed a controls partner to help establish its Australian manufacturing operation with new production lines and site infrastructure, and the relationship has had to keep adding and optimising lines without disturbing production already running on site. Metromotion Controls supported the initial setup and has continued to add, optimise and support production lines over the years, bringing process, packaging and site services onto common control and data interfaces so each addition extends one operating environment rather than a separate island. The scope spans plant services including boilers, refrigeration, trade waste, power monitoring and water usage monitoring, plus OEE, site data analytics and contextualised production data from lab equipment and other external sources.
Industrial automation engineering for Melbourne and Australian manufacturers, covering PLC, SCADA, control panels, commissioning and support.
OEE, downtime, historian and production reporting built from validated plant signals, so teams can see where the highest-impact yield and uptime gains are.
FAT, SAT, loop checks, startup support and defect closeout before production handover.
Remote and onsite support for PLC, SCADA, HMI, OT network and electrical control issues.
Speak directly with an engineer about scope, timing and technical constraints.