PLC programming and control panels
Industrial automation consulting: decide what to automate
Maybe a line keeps stopping, or maybe you’re looking at a capital plan and asking which parts of the operation are worth automating first. Solon’s industrial automation consulting starts with that question: what operating problem does this solve, what would it really cost, and is there a simpler fix? Then we make it concrete: a written specification with I/O, sequences and connections so integrators quote the same job. We supply equipment, build and program panels, and commission systems ourselves, so the advice and the delivery are connected. Our founders own and run an operation and deal with equipment purchases and control decisions themselves.
Why is the PLC faulting, SCADA losing contact or production data missing?
A pump won’t start, or an alarm conflicts with the equipment sequence. We follow signals through the written sequence and check planned acceptance checks against your requirements to find where the definitions disagree.
Why do the PLC and HMI show different valve states?
If the PLC says a valve is open and the HMI says it’s closed, we trace the signals and variables behind both readings. Our PLC programming and screen work address the definitions causing that mismatch.
Find missing sensor readings and gaps in historian records
A missing historian tag can leave a gap in your production records. We check instrument lists and network connections to identify which readings should be recorded and where they’re being lost.
Find communication errors between SCADA and field devices
A field device can have power and still send SCADA no usable data. We check communication protocols and define the signals each connection must carry before programming depends on them.
Equipment supply and controls programming
What does industrial automation consulting cover for PLCs and panels?
Need a new panel, replacement parts or programming for equipment you’re buying? We specify and procure new, used and refurbished equipment, and engineered systems. Solon builds and programs control panels, configures operator interfaces and supports commissioning and startup.
Check existing PLCs, sensors, networks and interlocks
Before buying components, we map your existing instruments, networks and interlocks to find gaps. We specify equipment and programming around those connections, so the upgrade fits the controls and equipment you’re keeping.
Which equipment and programmed control panels do you need?
Need equipment or programmed panels? We specify and supply equipment for your controls job, build and program panels, and stay involved for commissioning and getting the equipment running.
Communication protocols that carry historian readings and alarm signals
If a historian or alarm system can’t read connected hardware, we check which communication protocols the hardware accepts. We configure those connections, defining each signal’s route to the production record or operator screen.
PLC assessment through commissioning
PLC assessment and written specifications before manufacturing automation
Buying automation starts with deciding where it pays for itself: which stoppage, batch loss or labor bottleneck the project is meant to remove, what the alternatives cost, and what happens if you do nothing. Then we check what’s running. Our manufacturing automation consulting covers PLC code, HMI screens, network connections and instrument requirements. We write down the requirements and check the work against that scope before commissioning.
Assess current PLC code, HMI screens and SCADA settings
Before changing controls, we assess your current PLC logic, HMI screens and SCADA settings. That records what works now and what the equipment still needs.
Put interlocks, alarms and production-record requirements in writing
Which conditions should stop the equipment, and which readings need saving? We map production requirements to interlocks, alarms and historian records. The programming addresses those stop conditions and the records your team needs.
Control panel and operator screen checks during commissioning
During commissioning, we’ll compare programmed panels and operator screens with the equipment documents. Those checks use the written requirements to find field errors as the equipment begins running.
Controls documents for equipment quotes
PLC programming documents showing power, air loads and signal schedules
A load matrix listing power and compressed air for each component
Before buying, you’ll need each component’s power and compressed-air requirements. We record those loads from equipment documents in a matrix, so electrical and air connections account for the proposed equipment.
A signal schedule showing every PLC and HMI connection
Our interface schedule gives the crew connecting equipment a record of digital and analog signals between PLCs and HMIs. Each signal’s source, destination and purpose are listed.
A controls narrative spelling out equipment sequences and interlocks
What must happen before a pump starts or a valve opens? The controls narrative spells out sequence steps and interlocks for programming and commissioning checks, including when equipment can advance and when it must stop.
Equipment supply and automation costs
Questions about buying automation equipment and pricing the work
Can we buy equipment and controls programming from Solon?
Yes, equipment and programming can be bought together. We supply new packages as a dealer and distributor, used and refurbished equipment, and engineered systems. We build panels and program equipment when requested. See our brewery equipment page for equipment supply.
What can Solon check in our PLC, HMI and SCADA system?
We can assess the PLC logic, HMI and SCADA screens your equipment already uses, along with its instruments and networks. That includes interlocks, alarms and historian records. We also map operator interfaces and commissioning requirements.
How are our panels and programs checked before equipment runs?
Before the equipment runs, we compare the panels and programs we build with the written scope. We check them again at your operation during commissioning. Our commissioning and startup services include checking equipment as it begins running.
Can you upgrade our controls without replacing everything?
Yes, we start by mapping the control hardware you’ve already got. We specify upgrades through signal schedules and written equipment sequences, so new components fit the connections, power and production requirements of equipment you’re keeping.
How much will the controls assessment and programming cost?
Hourly advisory and review work and project roles priced as a percentage of the automation package need different scopes. Ask for the work and its pricing basis in writing. Compare that scope with the change orders and rework an unspecified project can generate.
Can you check the controls work with our existing integrator?
Yes, your existing integrator can stay involved. We write or tighten the controls specification, review code and panel submittals, and witness acceptance checks while your integrator builds. We also work alongside your supplier during commissioning, with the equipment requirements in writing for both teams.
Do we need to buy new PLCs for this project?
Your current PLCs may still fit the job. We evaluate your installed controllers, network and instruments before recommending replacement. Reusing suitable hardware is our starting point; new purchases need a reason in the equipment requirements.
PLC programming and electrical requirements
PLC languages, HMI screen standards and panel electrical requirements
Your controls need to match the equipment’s job and connection requirements. The PLC languages, instrument networks and published standards below give that work specific references for programming and checking.
Structured Text and Ladder code the next programmer can maintain
The next programmer may not have written your PLC code. We program and review Structured Text and Ladder under IEC 61131-3, checking state machines, interlocks and fault handling with maintenance in mind.
Select IO-Link sensors for temperature, pressure, level, flow and conductivity
Temperature, pressure, level, flow and conductivity sensors need to suit the demands of hygienic service. We select sensors, plan IO-Link master layouts and review instrument datasheets around the process measurement first, then match the hardware.
Address maps for EtherNet/IP, Modbus TCP and RTU, and IO-Link
Connecting equipment means agreeing on addresses and signals. We document EtherNet/IP, Modbus TCP and RTU, and IO-Link networks with address maps and signal schedules. Network design separates controls and business traffic, with connection responsibilities recorded.
Build SCADA and HMI operator screens using ISA-101 practice
An operator responding to an alarm needs to see the equipment state and what to do next. We develop screens to ISA-101 practice, using navigation and color to show state. Our interface schedules divide PLC, HMI and SCADA work across suppliers.
ISA-18.2 alarm priorities with a cause and operator action recorded
An alarm that keeps repeating needs a cause and an action. We check alarms against ISA-18.2 principles, documenting those details and a consequence-based priority. Repeated nuisance alarms are a controls design problem we address.
Panel electrical requirements and hazardous-area boundaries in distilleries
Before electrical design spending, we coordinate NEC (NFPA 70) requirements, review panel layouts and define distillery hazardous-area boundaries against NFPA 30 and 497 documents. That informs component selection.
Tank, cleaning and packaging controls
Food and beverage automation that connects tanks and packaging lines
A tank sequence needs to agree with the equipment feeding or emptying it. Our food and beverage automation work includes building and programming PLCs, HMIs and control panels, then commissioning the equipment. Written sequences give those checks a reference; our food plant automation guide covers food-processing applications. Also see food and beverage consulting for work beyond controls.
Batch recipes with sequence steps, stop conditions and restart rules
A product change may need new parameters rather than rewritten sequences. We structure recipe parameters, phase steps and starting conditions so new parameter sets can be used where practical. Batch sequences include holds, safe abort paths and defined restart conditions.
Control fermentation tank temperature and glycol cooling
Each vessel’s temperature loops and deadbands need tuning to its jacket. Setpoint schedules and crash-cooling stages account for glycol capacity when several tanks need cooling.
CIP cycle steps and cleaning interlocks checked against sensor readings
A CIP cycle needs to reach its required conditions before advancing. We program flow, temperature and conductivity checks into the steps. Interlocks separate cleaning and production paths; recorded measurements show whether the required cleaning steps happened.
Stage glycol pumps and compressors around production loads
Several tanks calling for cooling can load the same glycol equipment. We stage compressors and pumps around production load, define load-shedding priorities and smooth demand. The sequence accounts for equipment activity when commanding glycol equipment.
Filler, labeler and end-of-line controls that respond to a stopped machine
If the labeler stops, the filler needs to respond. We program line control, accumulation and machine handshakes between filler, labeler and end-of-line equipment. You keep the interface schedule documenting connections across suppliers.
Production reports with readings traced to tags and historian records
Production reports need identifiable equipment readings. We structure tags, configure historian records and develop reporting from the same readings operators see. Quality staff and management can trace reported numbers to their equipment source.
Consultants, integrators and panel suppliers
What do the consultant, systems integrator and panel shop each supply?
Who’s supplying panels, writing code and checking the work? Consulting defines scope and acceptance; integration delivers the working system. Solon supplies equipment and programmed panels alongside consulting, with responsibilities defined.
A systems integrator’s panels, PLC code, screens and startup labor
An integrator quotes panels, code, screens and startup labor against a defined scope. If you haven’t written the equipment requirements, the bid can become the scope by default. Differences found later may then become change orders.
Where the machine supplier’s or panel shop’s scope stops
A machine supplier or panel shop usually builds to its own equipment standard. Its scope often stops at the machine or enclosure. The connections to your other equipment still need defining, with someone responsible for coordinating them across suppliers.
An industrial automation consultant who writes specifications and checks acceptance
Integrators need a specification they can all price against. We write it, review code and panel submittals, witness acceptance checks and work alongside your team during commissioning, using your equipment requirements to check what suppliers deliver.
Before bidding, use our automation project scope checklist and beverage automation ROI guide. For sector-specific detail, see PLC programming for breweries on this page, distillery automation and winery automation. Our PLC and HMI integration page explains that work. See our food and beverage automation consultant guide for scope planning.
Talk through what to automate
Tell us your PLC, HMI and network, what keeps going wrong and what you want changed, or where you are in deciding what to automate at all. Include equipment details and your deadline. See our engineering consulting services for related work. To discuss your controls, talk to a consultant.