PLC programming, SCADA and HMI development for Australian food and beverage manufacturers. The systems that run a modern factory: sequencing CIP cycles, coordinating multi-stage batches and running the packaging lines.
PLC programming, SCADA and HMI development for Australian food and beverage manufacturers. The systems that run a modern factory: sequencing CIP cycles, coordinating multi-stage batches and running the packaging lines.
Rockwell and Siemens PLC programming, Ignition and AVEVA SCADA, HMI development. Structured, documented and built to be maintained by the site team.
We program in modular, testable structures so the system is supportable years after commissioning. ISA-88 is applied where sequencing or recipe logic is required, with reusable function blocks for motor control, valve manifolds, analogue loops and safety interfaces. Hardware typically includes Rockwell Allen-Bradley ControlLogix and CompactLogix, Siemens S7-1500, and distributed I/O such as Allen-Bradley Point I/O and Siemens ET 200SP. Naming conventions, alarm classes and permissive logic are defined early so that every machine cell behaves consistently. We also build diagnostics tags and historian-ready data models into the controls layer, so SCADA and reporting layers can consume reliable signals without rework later.
HMI and SCADA design follows ISA-101 principles, with screen layouts developed alongside the operators who will use them every shift. We prioritise high-contrast graphics, clear process context, consistent navigation and alarm handling that supports fast decision-making. Platforms include FactoryTalk View SE, Ignition Perspective, WinCC Unified and AVEVA System Platform. Process limits, interlock status and step progress are presented in a way that helps shift teams diagnose faults quickly. On a packaging line with recurring starve-and-block events, for instance, we visualise accumulation trends and handshake states between machines so bottlenecks are identified in minutes rather than hours. Role-based access, audit trails and change logs are built in to support GMP and internal governance requirements.
Legacy migration projects come with the constraint that production continuity is usually the highest priority. We migrate legacy Allen-Bradley PLC-5 and SLC 500, Siemens S7-300 and older SCADA nodes to modern architectures using staged conversion and test environments. Source code in Ladder, STL, FBD and structured text is reviewed for hidden assumptions, then rewritten with modern diagnostics and a maintainable structure. Protocol bridging via OPC UA, serial gateways or protocol converters is often required through the transition. A common scenario is replacing a legacy batching controller while retaining existing field instruments and motor control centres through a phased upgrade. FAT scripts, I/O simulation, cutover run sheets and fallback plans keep change windows controlled. After startup, we deliver the documentation and training that allows the site team to operate the system without depending on the original engineer being on the phone.
Standard libraries reduce defects, speed up new project delivery and make troubleshooting predictable. They also simplify training, because electricians and engineers see the same control patterns across different machines and lines on the same site.
Yes. We develop remotely using secured VPN and staging servers, then complete FAT and SAT on site. The remote development model is particularly useful for interstate work and lets the software mature before site access is available.
In many cases yes. Key screens can be redesigned, alarms rationalised, navigation improved and better diagnostics added while retaining the existing SCADA platform, provided the underlying infrastructure remains supported.
Speak directly with an engineer about scope, timing and technical constraints.
