Projects
Three written case studies, then shorter notes by industry, written for engineers: controller models, IO counts, protocols. Recent jobs in plainer words are on the home page.
What we work with. Siemens S7-1200 and S7-1500, Allen-Bradley ControlLogix and CompactLogix, Schneider Modicon, Omron, Unitronics, and the older generations of each. Ignition, WinCC, Citect and Node-RED for SCADA and screens. OPC UA, MQTT, Modbus, EtherNet/IP, Profinet and IO-Link. Where it fits, our own JasperX controller and cloud.
Case studies
Manufacturing, EcoSurfaces
Automated production line
Automation across the whole line: fewer injuries, fewer defects, lower labour cost, tablet-based monitoring in place of manual operation.
Read the case study
Water, Generator Property Management
Off-grid pump station
An 80 kW off-grid lift station: solar for the controls, VSD pump starts that stop the generator being overloaded, and web-based monitoring.
Read the case study
R&D, Gelion Technologies
Battery test rig
A custom NodeJS application on an industrial control layer, delivered in two weeks at 40% below the hardware-only spec.
Read the case studyMore projects, by industry
Plants, water and infrastructure
City of Newcastle
Summerhill SCADA
Delivered a centralised, fail-safe control and monitoring system using Ignition SCADA and Siemens PLCs to ensure strict EPA compliance for leachate management. Implemented a zero-trust MQTT architecture to integrate remote ponds, pumps, and valves across multiple sites. The system provides council operators with secure remote access, automated interlocking, and detailed historical data logging for regulatory audits.
Biodiesel Australia
Upgrade for EPA compliance
Biodiesel Australia required an electrical system upgrade to meet updated EPA regulations. Storage and reaction tanks were lacking level switches and condition alarms. We delivered the full package: electrical and control engineering design, schematics, PLC programming with HMI, supply, installation, and commissioning - all completed within a planned plant shutdown. Commissioning reports and full documentation are provided on handover.
Munzing Australia
Tank control system upgrade
Complete control system upgrade for Munzing’s ‘I-Release’ and ‘Sylvic’ production tanks. Delivered PLC-based multi-stage temperature control and variable-speed mixing, with a dedicated wireless network allowing full process control from a ruggedised mobile tablet anywhere on the plant floor.
Formit Services
Downtime tracking
Built the IIoT infrastructure for a rotational moulding facility, connecting two critical machines to a cloud-based monitoring platform. Machine-level gateways publish PLC data via MQTT to an IIoT platform, delivering live production counters, automated Downtime Pareto charts, and the data foundation for OEE calculation. Moved the client from manual tracking to data-driven operations.
Concrete panel manufacturer
Concrete batching automation
Automation of concrete batching and discharge for a panel manufacturing facility. Designed the full system architecture, developed PC software for recipe management and monitoring, programmed the PLC for batching execution, and built cloud infrastructure for remote process monitoring and data collection.
Machines, lines and new builds
Pacific National
Drop table control upgrade
Replaced an outdated PLC with a Siemens S7-1200 for a rail drop table and indexer at a train maintenance facility. Program conversion, IO mapping across 96 points, MCC integration for 20 outlets, VSD interface, and an IIoT gateway for remote monitoring. Full commissioning and operator training on handover.
EcoSurfaces
Calibrator line control panel
Custom panel for a stone calibrator production line handling high-power spindle motors, multiple VSDs, water recirculation pumps, and pneumatic solenoid banks at 415V three-phase. Dedicated motor protection circuit breakers, hardwired safety relay circuits, E-stop isolation, and light curtain integration for operator safety.
Belt conveyor
185 kW fluid coupling drive
Complete control and electrical design for a 185 kW belt conveyor with Voith TPXL fluid coupling and a 37 kW regenerative ABB ACS880 winch drive, across five voltage levels (1000V, 690V, 415V, 240V, 24VDC). Allen-Bradley CompactLogix 5380 with remote Flex I/O across five enclosures, 128 digital and 32 analogue signals, staged fluid coupling fill logic for smooth starts. Functional specification, FAT, single-line diagrams and schematics, on-site commissioning.
Noble Craft Distillery
Distillery control system
Full electrical and automation package for a new craft distillery in Brookvale. We designed the complete control system around a Siemens PLC and SCADA platform, with multi-layered safety interlocks for managing a hazardous, flammable environment. Automated temperature and flow control for the Hot Liquor Tun, Mash Tun, and fermenters ensures repeatable batch quality. IO-Link architecture reduced wiring complexity and created an expandable platform for future growth.
Noble Craft Distillery
Hazardous area MCC
18-outlet MCC for a craft distillery operating in an EEHA-classified environment. Over 15 DOL motor starters, VSD integration, intrinsically safe barrier circuits, and solid-state low-water cutouts for boiler protection. Electrical design, panel build, and commissioning.
Other work
Gelion Technologies
Battery storage monitoring
Gelion needed complete remote oversight of their Battery Energy Storage Systems. We engineered a unified data pipeline that integrated third-party inverters, battery management systems, and a Siemens PLC into a single data stream. A custom software layer on a dedicated Mini-PC transmits real-time data via MQTT to a cloud-hosted InfluxDB on AWS, giving Gelion’s team the insights needed for proactive maintenance and performance validation.
Lovells Springs
Robotic spring handling
Designed and implemented a robotic pick-and-place system for a spring manufacturing line. The system uses a video recognition camera to identify and locate springs on a pallet, calculates coordinates, and directs a Yaskawa Motoman robotic arm to pick and place them onto a conveyor. Custom software manages the full workflow: image capture, recognition, coordinate calculation, and robot commands.
Or send an enquiry with photos of the panel and the HMI. Most small jobs are quoted within two business days.