AutomationDirect’s SI Direct program provides expert system integration service to AutomationDirect customers, with particular emphasis on programmable controller, HMI, and motion products. These numerous ready-to-hire integrators, across the USA & Canada, have demonstrated specific product and application expertise and also receive ongoing training and equipping assistance from AutomationDirect.
To learn more about the SI Direct program or to find the SI Direct integrator near you, go to: www.automationdirect.com/si-direct
Hire a skilled SI Direct integrator for help with: • Electrical design • Software programming • Panel building and assembly • Turn-key systems • Field service needs • Consulting services
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O NLINE C ONTENTS
Click the headlines below in the digital edition for more article. https://www.controleng.com/supplement/global-system-integrator-report-digital-supplement
• Using a modular robotic platform to enhance safety, efficiency for battery manufacturer (A) – Concept Systems
• Navigating, learning lessons from the digital transformation in manufacturing journey (B) – Cybertrol Engineering
• Core architecture strategies for IT/OT network integration – E Tech Group
• Seven open-source interconnection strategies for empowering Industry 4.0 – Frenkel
• How developing a digital strategy improves automation efficiency – Grantek
• Going beyond physical boundaries and embracing 3D modeling – Gray Solutions
• Enhance processes and improving operations with PID loop monitoring – Interstates
• How manufacturers benefit by choosing a certified control system integrator – Patti Engineering
(SIs) play many roles in the automation and manufacturing space. They are often on the front lines devising and delivering solutions to their customers and giving them the results they desire and then some.
Like snowflakes, no two situations are alike. System integrators have a wealth of knowledge and experience at their fingertips. That helps them deliver productivity improvements powered by automation and the convergence of operations and information technologies.
Business has been good for SIs and is expected to reach more than $1 billion by 2032 according to a Market.US report.
That growth, however, will be because the market is changing, and SIs are
adapting to the new world. Information technology (IT) and operations technology (OT) continue converging and the rise of artificial intelligence (AI) has added several new opportunities and challenges to overcome.
Meeting the challenge head-on is what the SI lives for and their ability to see the situation from a different perspective is valuable. Their penchant for innovative and out-of-the-box thinking is a critical — and underrated — tool in their arsenal.
The system integrators highlighted in this issue in print and online have shown a tremendous capacity for meeting challenges for their customers and taking the initiative for engineers and manufacturers. GSIR
Chris Vavra is a former senior editor for WTWH Media.
“
Information technology (IT) and operations technology (OT) continue converging and the rise of artificial intelligence (AI) has added new opportunities and challenges.
“
Chris Vavra Vavra
(B)
(A)
Jose M. Rivera, Control System Integrators Association (CSIA)
The state of the SI industry remains strong
There has been a lot of turbulence in the system integrator (SI) industry due to events near and far, but engineers and integrators remain resilient.
The industrial system integration (SI) industry continues to benefit from favorable macroeconomic trends including near- and re-shoring, drive toward automatization to cope with a tight labor market and the need to deploy smart manufacturing to gain or maintain competitiveness. There are many challenges ahead as the landscape changes, particularly with the rise of artificial intelligence (AI) and there are some possible clouds on the horizon.
A changing SI landscape
The industrial SI industry started with the commercialization of the programmable logic controller (PLC) in the early 1970s. The automotive industry was the first vertical to adopt it, and its main applications were machine and assembly line control. The opportunity to expand the use of the PLC to other verticals and applications created an opening for entrepreneurial engineers to start their companies.
This created the SI market, one that remains composed of smaller companies. The Spring 2023 CSIA-JP Morgan survey said 52% of the represented SI companies had annual revenues below $10 million and 19% had annual revenues under $2 million. There are a few large independent system integration companies that have grown past the $200 million mark.
Mergers and acquisitions (M&As) have significantly increased. As an entire generation of SI company founders are moving into retirement, M&As provide them with one of several exit strategy options. There is demand for SI companies from strategic buyers.
One example are product companies that decide to extend their offers by delivering solutions. SIs provide an accelerated path to execution. Similarly, product or service companies may be asked by their multinational customers to provide extended regional or global support. Product and service companies (including SIs) may explore acquiring SIs to extend their global footprint or to extend the scope of their solutions.
The range of strategic buyers has increased. Deals in recent years have included acquisitions of SIs by automation equipment manufacturers, machine builders and by energy and infrastructure service providers.
Financial buyers, including private equity, have found the SI market. Value is added by consolidation and operational efficiencies to make the larger company more appealing to big strategic buyers. Some larger SIs have combined with private equity funding.
Expanding role for system integrators
SIs cover any sector that benefits from industrial automation. It is not intuitive to associate amusement parks or car washes with automation, but it is automation that makes it all work together. The scope of work delivered by SIs continues to expand. While control was and remains a key function of early industrial automation, today it represents a portion of what SIs deliver.
Data access, sharing and processing have become enablers of higher operational efficiency, safety and sustainability. SIs excel at accessing data at existing installations, which is often a patchwork of legacy, proprietary systems with more modern and open ones.
Expanding solution ecosystems
As the scope of solutions continues to expand, so has the ecosystem of suppliers. For example, robots have become more affordable and user friendly, making them more viable for many new applications and industries. More SIs are including robotics in solutions.
Are you hiring technical staff outside of traditional experience pro les?
We are We are not
Jose M. Rivera, CEO of the Control System Integrators Association (CSIA) since March 2015, works to help independent system integrators build better companies through the adoption of the association’s best practices guidelines. Image and graphics courtesy: CSIA
FIGURE 1: Hiring of technical staff by SIs outside of traditional experience profiles. CSIA EZ-Stats member survey, 2024-03-04.
The state of the SI industry remains strong
FIGURE 2: Use or intention to use offshore resources by SIs. CSIA EZ-Stats member survey, 2024-06-04.
Insights
System integrator insights
uThe system integration (SI) industry is expanding with the adoption of AI, automation and data sharing, allowing companies to improve operational efficiency and competitiveness across diverse sectors.
uMergers and acquisitions (M&As) have surged as SI founders retire, while strategic and financial buyers acquire smaller firms to extend global reach and consolidate their services.
Industrial automation has welcomed startups. Some of these companies provide key solutions at the data and data-security level. Digital twins of industrial plants provide many benefits for manufacturers. New tools help with the creation of these digital twins at brownfield installations. This includes conversion of paper documentation and creation of 3D models based on input from cameras that sometimes ride on drones. Artificial intelligence (AI) is the “new, new thing." See more below.
More business models
SI companies have traditionally been hired by clients to deliver specific projects. Some SIs have expanded these engagements delivering value to clients through an ongoing relationship. Sometimes they help manufacturers leverage the new data that they are getting access to by training operators.
SIs can provide services to set up and maintain the virtual twin of industrial plants. This demands new business models for the SIs and hiring of resources with backgrounds in data analytics, cybersecurity, and, just as important, the ability to consult with clients.
Attracting worker talent
In recent years manufacturers have struggled to recruit factory operators. SIs have faced a similar challenge recruiting talent. Leadership understands that their companies lack the brand recognition of larger manufacturing or automation suppliers. What helps SIs in the “war for talent” is an ability to provide engineers with the opportunity to build solid work experience through assignments across clients and industry verticals.
SIs have understood that it is important to have a consistent and proactive approach to recruiting. Several SIs have developed relationships with professional schools and colleges to provide internships, co-op programs and hiring for full-time positions. Regular engagements help them build their brands as an employer of choice at these schools.
Industrial automation solutions have become more “IT/software” centric. This has forced SI companies to pursue another type of talent. This
group has traditionally viewed ladder logic (traditional programming language for PLCs) and other programming approaches used by industrial automation as representing a “step down” for them. A shift toward “IT/software centric” by SIs will increase the odds to hire, retain and develop this highly sought-after talent pool.
Some SIs have revisited their approaches for hiring technical staff. From another monthly member survey, 24% of the participants have been hiring outside of traditional experience profiles.
Hiring offshore resources can help. In a monthly member survey, 25% of the respondents were doing this, and another 17% were contemplating doing so.
AI’s role in system integration
AI is poised to represent an inflection point, like the one provided by the internet or the electrification of the country more than a century ago. There are many things that need to be sorted out, and it will take years for this. SIs may not want to wait until then as they risk being left behind. In general, SI engineers tend to have a natural averse reaction to things they perceive as being “hype.”
In a CSIA monthly member survey, 19% of the respondents selected “I do not have time for fads” to the question “Are you using AI for internal processes?” This represents a minority as, in general, SIs tend to be tech-curious, and most seem to be intrigued by AI or at different levels of engagement.
If there is anything we have learned from two larger recent crises (2020 COVID-19 and the 2007 -2008 Global Financial Crisis), is nothing is certain. While the U.S. economy is doing fine, indicating a positive outlook for the SI industry, some global events could change things:
• Ukraine-Russia war: Russia invaded Ukraine at the end of February 2022, and there is always the possibility of further escalation.
• Israel-Hamas war in Gaza: This conflict started in October 2023. This is another conflict with the potential for further escalation.
• U.S. Presidential elections: A new presidential term inevitably brings uncertainty for a while.
The role of CSIA
The Control System Integrators Association (CSIA) was established in 1994 with the mission to help system integrators (SIs) build successful businesses and advance the impact system integrators have. Through the best practices and benchmarking (BP) manual and
Continued on pg. 54
Awarding excellence for 18 years System Integrator of the Year, 2025
E Tech Group, Matrix Technologies and Malisko Engineering received recognition from Control Engineering and Plant Engineering in this 18th annual award.
The three winners of the System Integrator of the Year award for 2025, from Control Engineering and Plant Engineering, WTWH Media, are:
• E Tech Group (over $50 million in system integration revenue)
• Matrix Technologies ($20 million to $50 million in system integration revenue)
• Malisko Engineering (under $20 million in system integration revenue)
Control system integrators regularly update and expand system integration capabilities and talent to help clients remain competitive, relevant and useful. In this accelerating world of technology developments and market demands, congratulations to the applicants who answered questions and assembled supporting documents to become System Integrator of the Year finalists. Thank you.
System Integrator of the Year 2025, judges, process
Meet the judges for the 2025 System Integrator of the Year award, who volunteer time for the challenging and rewarding selection process. They rank the finalists in three categories, divided by system integration revenue. Judges consider the assembled descriptions, metrics and examples of business skills (a thriving business enables engineering creativity), technical competence and customer satisfaction.
• Larry O’Brien, vice president of research, ARC Advisory Group, www.arcweb.com
• Don Roberts, principal, Exotek LLC, www.exotek.com
• Steve Rourke, co-founder, CFE Media and Technology (now part of WTWH Media)
Anticipating future system integration excellence
Award winners are announced in the Global System Integrator Report, a supplement to the November/December 2024 issues of Control Engineering and Plant Engineering. The award is dated for the next year in recognition of anticipated excellent system integration work to come. These articles highlight the 2025 System Integrator of the Year companies in three categories.
Edited by Mark T. Hoske, editor-in-chief, Control Engineering, www.controleng.com, WTWH Media, mhoske@wtwhmedia. com Amanda Pelliccione, marketing research manager, WTWH Media, administers the System Integrator of the Year program. Learn more; link to past winners: www.controleng.com/SIY
2025 System Integrator of the Year
Complex batch control project
Malisko Engineering is the winner in the under $20 million in system integration revenue category.
Malisko Engineering is the 2025 System Integrator of the Year award winner in the under $20 million in system integration revenue category. Dan Malyszko, vice president, Malisko Engineering Inc., discussed automation and control system integration achievements, projects, engineering development and metrics, among other topics.
In your 2025 System Integrator of the Year application, what were you particularly proud of?
We are incredibly proud of the journey Malisko has taken with the Entrepreneurial Operating System (EOS) over the past several years. Implementing EOS has been a game-changer for our team, aligning everyone in the company and ensuring we all row in the same direction. This structured approach has helped streamline our internal processes and allowed us to focus more intently on our core mission: delivering value to customers.
With EOS, we’ve become more cohesive, clear about our goals, and more disciplined in our execution. This has made us more responsive and adaptive to our customers' needs, ultimately increasing the value we provide. As a result, we’re better positioned to tackle complex projects and maintain high standards across the board. EOS has been foundational in helping us operate at a higher level, and that alignment played a big part in this recognition.
We are honored to be awarded the System Integrator of the Year for the third time in the last 15 years. This recognition reflects our constant commitment to one of our core values: Raising the Bar, a principle that drives us to continually push for excellence. We are immensely proud of the foundation laid 30 years ago by our founders, Steve Malyszko and Nancy Lange, along with all the dedicated individuals who have worked tirelessly to shape Malisko into the company it is today. This award is a testament to our passion for ongoing improvement.
Describe a system integration project
One of the projects we're most proud of is our work with Meati Foods, where we focused on the
control system for their commercial production facility producing a novel mycelium-based protein. This project presented unique challenges, especially in managing the precision fermentation process at scale.
We implemented a sequencer-based control system that allowed for batch-type control without a dedicated batch server. This approach provided the flexibility to run multiple recipes simultaneously, enabling dynamic adjustments and optimizing throughput without requiring extensive reprogramming.
A critical aspect of the project was elevating data visualization to provide real-time insights. While we utilized standard data monitoring and visualization tools, we spent significant time working closely with end users to model their data effectively. By focusing on an asset-based framework, we streamlined data reporting and empowered users to become “citizen data scientists,” giving them the tools to actively analyze and interpret their own data. What was especially rewarding was seeing how the data directly guided process decisions, impacting the startup’s financial outcomes—both positive and negative. This capability proved invaluable during commissioning, facilitating faster troubleshooting and ensuring smooth operations while having a real, measurable effect on their bottom line.
Projects like this demonstrate the value of our focus on precision control and data visibility, helping companies like Meati scale operations efficiently. Our work spans industries such as food and beverage, life sciences and consumer packaged goods, where delivering flexible, innovative automation is critical to success.
What system integration project methodologies do you use and why?
At Malisko, one of the key methodologies we focus on is fostering regular, proactive interaction with our customers throughout the entire project lifecycle. As customer engineering teams become leaner, they increasingly look to us not only for technical solutions but also for guidance in project management and execution. By adopting a more disciplined project management approach, we ensure that communication is consistent and transparent, allowing us to stay aligned with customer
Awarding excellence for 18 years
goals and adjust quickly to any changes in scope or requirements.
This regular engagement helps us anticipate challenges early and manage them effectively, reducing the risks of delays or cost overruns. We have evolved to include more frequent touchpoints and structured updates, which empower customers to stay informed and involved in key decisions without being bogged down by the day-to-day details. We’re able to provide a higher level of support and accountability, which has become critical as customers expect us to take a more holistic role in managing their projects.
Discuss long-term customer relationships
At Malisko, long-term relationships aren’t just important — they’re the only kind of relationships we’re interested in. We see ourselves as an extension of our customers' project teams, deeply embedded in their success. Our approach is guided by our core value: “Listen, Define, then Design.” We take the time to fully understand our customers' goals and challenges by listening carefully, defining the right approach, and then designing solutions that not only meet immediate needs but also position them for long-term success.
Another of our core values, “Servicing Manufacturing is Serving Society,” drives us to go beyond the technical aspects of our work. We view the industries we serve as vital contributors to society, and by helping our customers thrive, we contribute to the broader good. This perspective reinforces our commitment to building long-term partnerships where we provide continuous value, ensuring we’re not just completing projects but helping to sustain and advance the manufacturing sector as a whole. Through these relationships, we become partners in growth, providing ongoing support, anticipating future needs, and ensuring that our customers are
equipped to adapt to industry changes and technological advancements. This collaborative approach ensures mutual success and shared achievement over time.
Please share a long-term goal
One of our long-term goals is to achieve sustainable growth while ensuring that our company culture adapts to the evolving preferences of each new generation. As the workforce changes, we’re focused on fostering a culture that resonates with our team, maintaining our core values while staying flexible and responsive to what our people need to thrive. We’re committed to growing with the right kind of customers, building long-term relationships with companies that align with our values and vision. This approach ensures we expand in a way that benefits our business and the customers we serve. It’s about balancing growth with a focus on meaningful, enduring partnerships.
Provide metrics and explain their importance
Key metrics include:
• Project success rate: 96% of projects completed on time and within budget. This highlights our ability to deliver results efficiently, a critical factor in maintaining loyal relationships with our customers.
• Customer retention rate: 98% customer retention over the past year, reflecting the strength of our long-term relationships and customer satisfaction.
• Revenue growth: 13% year-over-year increase. This showcases our sustainable growth, competitiveness and ability to expand our business while maintaining quality. GSIR
Dan Malyszko is vice president, Malisko Engineering Inc.
MALISKO ENGINEERING INC. leadership team from left to right: Dirk Disper, director of business development and sales; Steve Schneebeli, senior director of engineering; Dan Malyszko, vice president; and Jess Freels, president. As Malisko celebrates 30 years, this leadership team is dedicated to upholding the values and spirit that have driven our success from the beginning, guiding us into a future of innovation and excellence. Courtesy: Malisko Engineering
“By focusing on an asset-based framework, we streamlined data reporting and empowered users to become 'citizen data scientists,' giving them the tools to actively analyze and interpret their own data.“
2025 System Integrator of the Year
Multi-site IT/OT network project
In the $20 million to $50 million in system integration revenue category, Matrix Technologies Inc. is the winner.
Matrix Technologies Inc. is the 2025 System Integrator of the Year award winner in the $20 million to $50 million in system integration revenue category and discussed automation and control system integration achievements, projects, engineering development and metrics, among other topics.
In
your 2025 System Integrator of the Year application, what were you particularly proud of?
The Matrix Team is proud of the accomplishments and continuous improvements we implemented in the years after our last win. It would be easy to rest on our accomplishment and say we had “arrived” once we won the award, but that has never been our attitude. We recognize that only through constant re-evaluation of our processes and systems will we keep our position of leadership in the market.
The most significant thing we accomplished this year was to implement the employee stock ownership plan (ESOP). This is a huge step forward in the engagement and reward of our team in our success and we will reap the benefits in the years to come.
Describe one or more system integration projects
One project mentioned in the application was the Corporate Infrastructure Rollout across 22 client locations. This project encompasses many aspects of the expertise we bring to the market, as well as the industry focus overall. As the client continued to look for ways to gather actionable data from plantfloor operations, it also recognizes that in many cases the existing infrastructure is inadequate to gather and protect that data. Cybersecurity, reliability and robustness are all key aspects to a solid infrastructure, and this project allowed Matrix Technologies Inc. to help our client achieve these goals.
menting a new network system into the middle of an operational production facility is the equivalent of open-heart surgery. We stop the entire system, install the new equipment and then bring it all back to life over a brief period. Each of these implementations has been flawless, and that speaks to the level of skill and knowledge our team has in this industry, and the strong level of partnership we develop with our clients who trust us with their most important projects.
What system integration project methodologies do you use and why?
There is an overarching need in every project to ensure success, and that is clear requirements and expectations. Without this, projects have a very good chance of failing, or at least not meeting someone’s unstated expectation. Part of our project process has been the development of a clear scope of work and functional specification for every project. This is the only way to ensure all requirements are documented and that the system meets those requirements. This was true 20 years ago, and still is today. What has evolved is where and how those requirements are developed. Years ago, this was often assembled by our clients. Today, with limited staff and tight timelines, our clients turn to us to develop these scopes and requirements. Client scopes and requirements for projects are still just as important as ever, but we now get involved earlier than ever in developing them.
How have customer expectations for system integration projects changed?
www.matrixti.com
We understand how to architect these robust networks and have a deep understanding of all the attached equipment, including programmable logic controllers (PLCs), drives, human-machine interfaces (HMIs), databases and connected devices. Imple-
As the more experienced staff retires and leaves the client sites and locations, clients expect more from their system integrator partners. In some cases, the newer engineers simply don’t have the knowledge of old systems they are charged with supporting or replacing, so they often turn to system integrators to help understand what they have and how to either maintain it or replace it. This often leads to “pre-engineering” opportunities to help define a project and its requirements. We have formed new organizations within Matrix to help focus on this
upfront engineering needed to close the gaps that are becoming more prevalent with our clients.
How important is developing long-term customer relationships and why?
Our entire business strategy is built around forming long-term partnerships with our clients. The more we can be considered an extension of their team, the more we can service their needs. As we get involved in the early-stage planning as mentioned earlier, we get a better picture of the workload to come next year and later years, and we can staff appropriately to handle this workload. Our clients know we are there to meet their needs, and they are willing to send more projects our way. Consistency around project teams and project execution leads to better quality and lower cost for our clients, which is what our clients are seeking from their partners.
Are supply chain issues affected projects in any way?
Two years ago, this would have been a resounding “yes.” However, these supply chain issues have eased greatly, and we do not see significant effects on our projects any longer.
How are you helping younger engineers with automation and control system integration?
We have focused in the past year on improving our onboarding programs for new hires. This process is outlined in our application. Specifically, pairing up our younger engineers with project leaders that have the knowledge ensures an efficient knowledge transfer, while also providing for project oversight. We also have invested in additional training for employees that puts them in real world plant situations to build the troubleshooting and communication skills that are just as important as technical skill training. In addition to training and mentoring, we make sure younger engineers have the opportunity to visit client sites and get a real-world view of the projects they support which also helps build an understanding of the role they play in making projects successful.
Please share a long-term goal for the company
Following our EOS planning process, we focus on re-investable income. This is income that we use to invest in tools, technology, and employees to allow us to stay ahead of the competition. If we do this, we know we will be able to provide high-quality,
Awarding excellence for 18 years
PLANT-FLOOR NETWORK closet for information technology/operational technology (IT/OT) use samples the complexity of communications, part of a corporate infrastructure rollout across 22 client locations. Cybersecurity, reliability and robustness are all key aspects to a solid infrastructure. Courtesy: Matrix Technologies
efficient, and reliable solutions for our clients. It is not just about making money that will be shared as bonuses and salary, but rather money that can help us meet our core purpose of “Enhancing People’s Lives…Every Day.” This includes our employees, clients, and communities, to name a few.
Provide a few metrics and explain their importance
Key metrics include:
• Team Matrix has worked diligently over the past four years focusing on our client partners within seven specific market sectors. Today, this has resulted in a higher level of client retention and satisfaction from those key client relationships where Matrix continues to meet client’s needs when scored in client feedback. Our clients rate our work above average at a 4.60 (4 is meeting expectations). Matrix is proud of the quality of service we provide and continue to grow our relationships with our partners.
• With 784 days, or 1.2 million hours, without a lost time incident and a 0.48 experience modification rate (EMR), we continue to set high standards for workplace safety. This achievement, along with being awarded the Highwire Gold Star Safety Award in 2024, underscores our unwavering commitment to the well-being of our team and our dedication to maintaining the highest safety protocols across all operations.
• Employee engagement and retention are crucial to the success of Matrix Technologies and the satisfaction of our clients. Over the past few years, we've made significant efforts to enhance the employee experience, and our recent engagement survey reflects this, with an impressive 82% engagement score, with improvements for the past five years. Our transition to an ESOP is the latest step in recognizing and rewarding employees for their long-term commitment to Matrix. GSIR
Dave Blaida, PE, is CEO and president at Matrix Technologies.
PE, is CEO and president at Matrix Technologies, a 2025 System Integrator of the Year winning company. Courtesy: Matrix Technologies
DAVE BLAIDA,
2025 System Integrator of the Year
E Tech Group, New digital twins
E Tech Group wins in the over $50 million in system integration revenue category.
ETech Group is the 2025 System Integrator of the Year award winner in the over $50 million in system integration revenue category. The company discussed automation and control system integration achievements, projects, engineering development and metrics, among other topics.
In your 2025 System Integrator of the Year application, what were you particularly proud of?
It’s a great honor to have been selected as the 2025 recipient of the System Integrator of the Year award. Our submission outlines our strong mission and purpose statement, which guides our company’s focus and our long-term vision for the future.
At E Tech Group, we are particularly proud of our team whose immense and diverse talent, collective energy, commitment and excitement, is foundational to our ability to identify, design and deliver innovative solutions achieving excellence in every project. Our company fosters a culture for team members to thrive, which results in outstanding service for all of our clients.
Describe
one or more system integration projects
A recent digital twin project completed for a prominent manufacturer highlights E Tech Group’s commitment to designing innovative, effective solutions for our clients. This project makes us particularly proud.
When a prominent manufacturer wanted to upgrade its production line’s digital twin, E Tech Group software developers delivered an innovative solution using a 3D video game development platform. The twin mimics the behavior of its real-life counterpart in real time and is visible in a 3D environment via web interface.
The digital twin has significantly improved production line operation and troubleshooting, saving our client an estimated $5 million annually in reduced downtime and travel costs. The project is ongoing as our client continues to request additional digital twins of new production lines.
One of the key features of this project is its configurability and control system agnosticism. This
means that the digital twin can be adapted to various systems and configurations, making it a versatile tool for different manufacturing environments.
The success of this project can be attributed to our team’s diverse technical background, which extends outside of the manufacturing industry. For this specific project, this expertise allowed us to confidently select a 3D video game development platform – an innovative selection that ultimately incorporated the functionality required to better meet our client’s needs.
What system integration project methodologies do you use and why?
Our fundamental methodologies stem from adherence to the Control System Integrator Association’s (CSIA) https://controlsys.org Best Practices & Benchmarks Manual. We believe that these best practices ensure that our projects are managed efficiently, risks are mitigated and quality is maintained throughout a project’s lifecycle. Our commitment to CSIA best practices has led to multiple E Tech Group locations undergoing and passing the required rigorous third-party audits, achieving consecutive certifications. We are currently pursuing a groundbreaking initiative to achieve CSIA certification across all our offices, setting us apart from other large integrators who typically certify only one or a few locations.
E Tech Group’s company culture fosters strong support for inquisitiveness, innovation and perseverance, with an underlying deep commitment to excellence for every project and every customer. We continue to keep pace with the rapid advancements in technology and the changing needs of our clients. For example, we have hired and trained engineers for emerging roles in cybersecurity, industrial IT, advanced software and data analytics to support clients as they adopt Industry 4.0 digital transformation.
We embrace a company-wide focus on continuous improvement and innovation. Our unified Quality Management System (QMS) called Playbook 2.0, is designed to standardize project execution across the entire company. This system encourages regular review and refinement of our processes, products, and services.
How
have customer expectations for system integration projects changed?
As manufacturers strive for complete digitalization of their operations, clients are increasingly relying on system integrators for long-term strategic guidance and planning. At E Tech Group, our wide-ranging capabilities and expertise allows us to embrace this opportunity as we strive to become trusted advisers to all of our clients.
How important is developing long-term customer relationships and why?
At E Tech Group, we believe that building longterm, trust-based relationships with our customers is foundational to the success of both our businesses.
E Tech Group's extensive capabilities and vast experience in automation and information solutions uniquely position us to nurture long-term relationships, serving as our clients’ main automation partner. In this role, we collaborate closely with a client to develop a strategic roadmap aligned with their long-term goals, laying a foundation that supports and fuels their growth. As main automation partner, we gain a comprehensive understanding of a client’s processes and facilities, which deepens our insight into their pain points. As a result, we can provide more effective, comprehensive solutions that not only protect and update their systems but also eliminate inefficiencies. These tailored, forward-thinking strategies help our clients maintain and grow their competitive edge.
Are supply chain issues affected projects in any way?
We are not being impacted by any supply chain issues at this time. We are observing a trend where clients are increasingly favoring onshoring practices.
How are you helping younger engineers with automation and control system integration?
E Tech Group's learning management system, called E Tech University, is a well-established internal educational tool integral to both our onboarding process and a resource that supports ongoing internal education. It offers a variety of technical courses, including control systems, networking basics, industry overviews and product-specific training. These courses are designed to help engineers gain valuable experience and develop new skills.
As part of our E Tech University, our onboarding training process for engineers focuses on E Tech Group’s standards and best practices. The training cul-
Awarding excellence for 18 years
E TECH GROUP offers an in-depth assessment of a facility’s infrastructure, providing a detailed vulnerability report and individualized remediation plan.
Courtesy: E Tech Group
minates with a comprehensive project where the engineer must program a complete programmable logic controller/human-machine interface (PLC/HMI) system in compliance with E Tech Group standards. The project is mentored and judged by a senior member of the engineering team. This training is completed before a new engineer is assigned to their first project.
Please share a long-term goal for the company
One of E Tech Group’s long-term goals is to continue expanding our global footprint. We currently have offices throughout the United States, as well as in Canada and Mexico, and we have conducted business in 12 countries. Our next strategic move involves expanding our office and resource availability to continue meeting the growing needs of our international clients.
Please provide a few metrics
Three metrics show growth over a relatively short period of time:
• We look at growth over the past seven years, compound annual growth rate (CAGR) of revenue at 36%.
• We expanded from one office in Cincinnati to 25 offices over seven years.
• Our headcount is now over 600. GSIR Matt Wise is chief executive officer, E Tech Group.
E TECH GROUP CEO
MATT WISE addresses the crowd at Power Week, an annual company event focused on training, best practices and networking for employees. Courtesy: E Tech Group
FIGURE:
EVENT OVERVIEW:
The Advanced Automation Forum (AAF) is a two-day event designed to accelerate digital transformation in manufacturing through collaboration between system integrators, end users and product manufacturers. Taking place on April 30th and May 1st, 2025, this forum will offer hands-on, practical insights into the future of manufacturing, focusing on real-world strategies, successful case studies, and actionable solutions. During the event, we will recognize the important contributions of top system integrators.
KEY FOCUS AREAS:
• The practical implementation of smart manufacturing
• Data-driven decisions
• Securing connected devices through collaborative cybersecurity
• IT/OT alignment
• Upskilling the workforce
• Overcoming integration challenges
• The tools required to support sustainability initiatives
System integrators expand, vital, scarce automation skillsets
WTWH Media, publisher of Control Engineering, Plant Engineering, and the Global System Integrator Report, is proud to present the 2025 System Integrator Giants. Featured on the following pages are the top 75 system integrators from the Global System Integrator Database, ranked solely by their total system integration revenue for the most recently completed fiscal year.
Over the past five years, the System Integrator Giants program has captured significant industry trends, revealing shifts in revenue distribution, workforce growth and emerging business challenges that have influenced the field.
Larger system integration firms, more engineers
From 2021 to 2025, the dominance of larger firms in the market has become increasingly apparent. The percentage of companies generating more than $100 million in total gross revenue rose from 12% in 2021 to 24% in 2025. This seems to indicate a competitive environment where scale is a clear advantage for sustained growth. On the other hand, the share of smaller integrators (with up to $25 million in total gross revenue) declined from 60% to 39% over the same period, reflecting a potential consolidation of market influence among larger players.
2025 System Integrator Giants: Examining the shifts in revenue, talent, and industry pressures over the past five years.
between 2021 and 2025, underscoring the expanding demand for complex integration projects.
The role of engineering talent has been vital in this growth. The average number of automation and control engineers primarily assigned to system integration projects rose from 105 in 2021 to 168 in 2025. This increase suggests a strategic emphasis on enhancing workforce capacity to meet growing project complexities and client expectations.
System integrators need, supply automation engineering skills
The industry also has faced evolving challenges. While the COVID-19 pandemic severely impacted operations in 2022, recent years have seen staffing issues, particularly the recruitment and retention of skilled young engineers, come to the forefront. Rising costs for labor and materials have also been significant concerns for many firms.
System integrator revenue increases 86%, 2021-2025
To stay competitive, educational and professional development programs have played an essential role. Despite slight declines in participation, strategies such as paid conference attendance and internal mentoring continue to be prioritized, albeit with adjustments due to changing budgetary considerations.
For ranking purposes, “system integration revenue” is defined as revenue derived from automation integration services after deducting the costs of all off-the-shelf products, including hardware, software and equipment. Notably, total system integration revenue has shown a positive year-over-year trend, with the aggregate value increasing by nearly 86%
This year’s listing exemplifies the resilience and adaptability demonstrated by top system integrators as they navigate economic fluctuations, workforce changes and technological advancements. The leaders showcased in the 2025 System Integrator Giants listing have embodied the innovation and strategic foresight needed to excel in this dynamic field. GSIR
ONLINE
See a ranking of leading concerns among System Integrator Giants, 2024-2025, ranked by largest changes.
The data for the System Integrator Giants program is voluntarily provided by participating companies between June and September each year. Companies submit information on total gross revenue and total system integration revenue for their most recently completed fiscal year. Participation varies from year to year. For more details, visit www.controleng.com/giants. Amanda Pelliccione is marketing research manager, WTWH Media LLC.
Aurora, OH, United States
Bottling, canning, brewing, distilling; building envelope, controlled atmosphere; chemicals, petrochemicals; electronics, semiconductor; food, beverage; glass, stone, clay; household, personal care products; information and communication systems; life sciences, biotechnology; material handling, logistics, warehousing; mining, aggregates, cement; oil & gas refining; paints, coatings; pharmaceuticals; pipelines; plastics; pulp, paper, converting; quality control, test and measurement; transportation equipment; water, wastewater; wood, lumber
bottling, canning, brewing, distilling; chemicals, petrochemicals; food, beverage; household, personal care products; information and communication systems; life sciences, biotechnology; mining, aggregates, cement; paints, coatings; pharmaceuticals; plastics; water, wastewater
From chaos to clarity: The project management edge GIANTS SYSTEM INTEGRATOR In Action
Steve Orth, EOSYS Vice President of Automation
The EOSYS Group provides custom industrial automation and digital transformation solutions to Fortune 500 companies and major industrials across the United States. In addition to technical capabilities, EOSYS provides consistent project management to ensure all projects follow our proven methodology.
How does EOSYS move projects from chaos to clarity?
Early in my career, one of my coworkers observed that there are two types of engineering personalities: those who amplify problems and those who simplify them. System integrators with good project management ensure that work is efficiently organized, issues are quickly identified and resolved, and project status is clear to customers and team members. Those without are just rolling the dice by hoping things go well, while inadvertently putting their customers at unnecessary risk. We strive to always be one who simplifies.
Tell us about “the project management edge?” How does good project management provide an advantage?
Most customers already assign a project manager or lead to their internal project team, but often that individual is new to the role or lacks awareness of the unique needs of the automation or digital transformation scope. The system integrator’s project manager acts as an extension of the customer’s project management staff by filling the gaps in knowledge, mitigat-
ing risks, and ensuring efficient communication. Ultimately, our job is to guide our customers to the most efficient project execution that will give them an edge over their competition.
Before working with customers on an automation, controls or system integration project, what do you want them to know about project management?
Customers who consider project management to be an unnecessary cost have probably not worked with a good project manager. When executed properly, a PM’s cost should easily be offset by the efficiency he or she enables for the engineers or developers. This reduces risk and keeps everyone on the team doing what they love and are absolutely best at.
Please provide examples and quantify, if possible, why these topics are important for customers?
While it may be tempting to skip steps, sticking to a proven project methodology ensures project success. I once had a customer request that we forego a factory acceptance test because the schedule was too tight and he didn’t see the value. After some convincing, he reluctantly agreed to squeeze it in. In that FAT, the customer’s production team identified some critical requirements that had never been communicated to us. Because we pushed to follow our proven process, we had time to cut in these new features and the startup schedule was unaffected. GSIR
“System integrators with good project management ensure that work is efficiently organized, issues are quickly identified and resolved, and project status is clear to customers and team members.“
The EOSYS Group is an automation system integrator and a Control Engineering and Plant Engineering System Integrator of the Year in 2023.
https://www.eosysgroup.com
CAPABILITIES
AS A LEADING INDUSTRIAL CONTROL
INTEGRATOR, EOSYS designs plant information systems and plant floor control systems that assist clients with optimizing their manufacturing operations to improve overall performance.
ENGINEERING SPECIALTIES
• Automation Solutions
• Industrial Digital Transformation
• Panel Fabrication
• Field Installation Services
• Operational Technology INDUSTRIES INCLUDE
• Food & Beverage
• Distilling & Spirits
• Consumer Packaged Goods
• Energy
• Pulp & Paper
• Chemical
• Automotive
OFFICE LOCATIONS
NORTH AMERICA
• Nashville, TN
• Huntsville, AL
• Minneapolis, MN
• Atlanta, GA
• Cincinnati, OH
Revolutionizing digital transformation with DxOps Transformation GIANTS SYSTEM INTEGRATOR In Action
Jessica Buonopane, Customer Advocate - Digital Transformation, RoviSys
Digital transformation is essential for manufacturers today, yet statistics show that more than half of these initiatives fail due to unclear strategies, poor execution, scope creep, and a lack of adaptability. RoviSys, a leader in automation and information solutions, is changing this with its DxOps Transformation suite, designed to increase success and adoption across the digital journey.
Digital transformation guidance
Clear practical steps toward digital transformation
"We've created a suite that makes digital transformation both achievable and sustainable," says John Vargo, Director of Digital Transformation at RoviSys. "With a focus on clear, practical steps, companies can confidently move forward, knowing they are on a path to long-term success."
ROVISYS AUTOMATION and information solutions drive productivity, improve product quality, increase asset utilization and integrate technology. Customers turn to RoviSys for proven, reliable information management, manufacturing automation, control systems integration, building automation, warehouse automation, enterprise and industrial networks, MES, and Industrial AI. rovisys.com
CAPABILITIES
The suite offers a structured, repeatable approach that helps manufacturers navigate their transformation journey, from initial assessments to long-term optimization. Built on over a century of combined experience, this suite translates deep industry knowledge into actionable processes that enable companies to avoid common pitfalls and achieve measurable outcomes. With a flexible, scalable design, it can be applied to small, single-site discrete processes or multi-site complex manufacturing operations, supported by RoviSys resources located around the globe.
What makes the suite truly unique is its adaptability —offering multiple entry points, allowing companies to start wherever they are on their digital transformation journey. Whether a company is just beginning to explore digital strategies or is looking to enhance and sustain existing investments, the suite provides a tailored approach that meets their unique needs.
Unlike many initiatives that lose momentum after implementation, the suite emphasizes continuous value realization. It combines strategic consulting, adaptive delivery, and ongoing support to ensure that digital investments not only deliver initial results but also drive continuous improvement and maximize ROI over time.
Practical framework for any digital transformation technologies
The launch of the DxOps Transformation suite represents a new standard in digital transformation. With its practical, technology-agnostic framework and adaptability to any starting point, RoviSys enables manufacturers to confidently tackle complex challenges, adapt to change, and maintain a competitive edge in an evolving market. GSIR
For more on how the DxOps Transformation suite can revolutionize your digital strategy, visit www.rovisys.com/capabilities/digital-transformation or email digital.advisors@mail.rovisys.com.
“More than half of digital transformation initiatives fail due to unclear strategies, poor execution, scope creep, and a lack of adaptability.“
• Process Automation
• Building Automation
• Discrete Manufacturing Automation
• Warehouse Automation
• Control Systems Integration
• Manufacturing Execution Systems (MES)
• Industrial Network Solutions
• Building Management Systems
• Electrical Power Management Systems
• Analytics for Business & Process
• Electrical & Instrumentation Design
• Enterprise Networking
• Software Development
• Consulting
OFFICE LOCATIONS
NORTH AMERICA: Ohio, North Carolina, Texas, Michigan, Massachusetts, California, Georgia, Illinois, Virginia
ASIA-PACIFIC: Singapore, Taiwan, Indonesia, Malaysia, Japan
EUROPE: Nederland, Ireland
Ian Burns, Applied Control Engineering (ACE)
Accelerating innovation with digital twins
Digital twins offer many benefits ranging from new workforce training to the ability to accelerate innovation and continuous improvement and are flexible and versatile.
For industrial facilities to remain competitive, it is necessary to invest time and money into automating and optimizing processes and modernizing outdated production equipment. But automation projects are often challenging to execute as budgets are limited, development windows are typically short, and there is not much tolerance for downtime or other risks that could impact production. One often-overlooked tool for tackling these challenges is pairing the development of a digital twin with an automation project.
Whether it’s building a new system or upgrading existing components, companies can use a digital twin to simulate and analyze a system’s performance under various conditions. The results of the simulation will help reduce many implementation risks since potential issues can be identified and addressed before ever reaching the live system. Operators can also be trained using the virtual system, ensuring a smooth startup process when changes are made.
The use cases for a digital twin go well beyond a single automation project. These digital systems offer many post-implementation benefits ranging from new workforce training to the ability to accelerate innovation and continuous improvement.
Since digital twins are so versatile, considering these real-world scenarios to understand their capabilities and benefits.
Piloting process changes without interrupting production
• Understand how digital twins can improve automation processes.
• See three case studies on how digital twins helped companies.
• Learn how simulation can accelerate time to market
For one science and technology company producing specialty gases used in semiconductor manufacturing, minimizing downtime when deploying necessary changes to their automation and control system was crucial. As the team worked with the organization to design and build their distributed control system (DCS), they decided this project was a good opportunity to test the waters with a digital twin for one part of their process.
A medium-fidelity digital twin of a filling process was developed as part of their production, which required the most operator interaction. The company then used the digital twin to pilot various process changes, perform sandbox testing, and execute more comprehensive operator training prior to installation of the new DCS. With this ability to test changes and troubleshoot issues in a virtual environment, they were able to minimize the risks and costs associated with performing numerous physical trials with their new system. With the digital twin configured, the company can continue to use the system to onboard operators more effectively.
Reducing risk for a large-scale DCS modernization
When a large chemical manufacturer was having trouble obtaining spare parts and support services for their 20+ year old DCS, the plan was to execute a multi-phase modernization. Since the company had very limited downtime windows to work with and their process includes an exothermic reaction with potentially dangerous materials, the integration team proposed the idea of simultaneously developing a digital twin to mitigate risk during this upgrade.
The company was interested in the digital twin for a couple reasons. First, since it is difficult and dangerous to train operators on abnormal situations with the live system, making the ability to conduct this training in an identical digital environment was attractive. Second, because of the limited time available for cutover to the new system, they liked the idea of performing extensive testing and operator training in the simulated system before the new DCS was live.
They developed a digital twin that was a cross between a medium- and high-fidelity system that incorporated input from site operators and engineering staff to ensure the simulated system really did mimic their experiences with the plant.
To help the company better plan for future changes, procedures were developed for the customer to concurrently update the digital twin as changes are made to the DCS. The customer also learned how to test new changes on the digital twin and then move the changes to the production DCS once they were ready.
Using simulation to accelerate time to market
As part of a multifaceted effort to release new process technology and expand the markets they serve, a global leader in manufacturing stationary fuel cell platforms needed a way to make process changes that would help them quickly get to market. While they were developing this new technology, this company was also embarking on a change to their automation platform vendor, further complicating what they needed to do. To address these concerns, ensure a smooth transition as their process dynamics changed, and provide an environment where they could test new ideas before the equipment was built and later once it was built without risking damage to the physical equipment, an environment with a simulation platform was configured.
Using the new simulation platform, the customer started testing and verifying their control system code before receiving their new control hardware and before the skid was manufactured, accelerating development time. They also could now test small segments of their process and ensure system quality before moving on to the next step.
With the digital twin, they eliminated the need for extensive small-scale piloting. The virtual testing environment also allowed them to better protect their valuable hardware since the hot processes they
run can damage a fuel cell if something does not go right, which is more likely to happen in the early stages of the pilot process. Overall, this company can now scale up faster as they’ve eliminated the need for some of the physical steps in the development process and they are now spending less time on process development since they can use their digital twin as a test environment instead of their physical hardware.
Digital twins drive automation project efficiencies
By implementing a digital twin alongside an automation project, industrial facilities can experience a wealth of benefits. As shown through the examples in this article, use cases range from simulating and analyzing performance to optimizing processes without risking damage to physical equipment to the ability to train operators on both normal and abnormal operational conditions, all in a simulated environment.
By incorporating the ideas highlighted in these digital twin use cases into the next automation project, companies can reduce implementation risks, costs and time while ensuring a smoother transition as changes are made. GSIR
Ian Burns is president at Applied Control Engineering.
Control system engineers review a digital twin model (right) against an HMI process graphic (left).
Courtesy: Applied Control Engineering (ACE)
u
Insights
Digital twins insights
u Digital twins help industrial facilities reduce risks and costs by simulating system performance and training operators before live deployment.
u By using digital twins, companies can accelerate innovation and continuous improvement, optimizing processes without risking physical equipment.
Andrew Harris and Matt Thiel, ACS
Demanding automation trends that make integration planning essential
Automation is revolutionizing testing and manufacturing facilities, but the increased complexity of designing and integrating automated systems can pose significant challenges for manufacturers.
Automation is transforming testing and manufacturing facilities. It’s being used to streamline processes, enhance precision and repeatability and improve operator safety. However, the increased complexity of designing and integrating automated systems makes it challenging for manufacturers to realize their full benefits.
The role of a systems integrator is crucial to helping companies navigate the available automation hardware and software options while considering the concurrent pull of automation trends and company goals and constraints.
Companies that start the process with equipment selection often end up with an inefficient patchwork system that’s more expensive to build and maintain. They lose the opportunity to design an optimized, automated system where all components work together as a harmonious, cost-efficient solution.
Four automation trends pushing process modernization
It’s vital to start with front-end planning guided by a systems integrator experienced in assembling optimized and automated subsystems. This approach increases the organization’s opportunities to maximize its return on the investment in automation.
TREND #1: Modernizing aging production lines
Many manufacturing companies struggle to integrate modern technologies into outdated systems in facilities and production lines that were built decades ago. Manufacturers often do not have the bandwidth to become familiar with the latest tool advancements.
Without understanding the evolution from automated guided vehicles (AGVs) to autonomous mobile robots (AMRs), they may follow a path that adds constraints rather than alleviates them.
AGVs require extensive infrastructure, including underground sensors and power systems. In contrast, AMRs provide greater flexibility because they’re not physically integrated with the facility.
Other advances in robotics offer still more choices for effectively modernizing a facility or production line. For example, collaborative robots (cobots) provide a flexible, cost-effective option to handle simple tasks safely around human operators. Their limited payload and slower speeds mean they’re not always the right choice, however.
More sophisticated safety sensors improve robots’ spatial awareness and allow real-time environmental mapping to detect potential unexpected
FIGURE 1: To ensure operator safety, the ACS team designed physical and programmable mechanisms, with the robot operating in a three-sided fenced area that runs only when gates are securely closed. Images courtesy: ACS
obstructions, letting them operate in smaller buffer zones. The growth of EtherCAT, with its high-speed communication and precise synchronization, is another advanced technology that offers significant benefits but can come with implementation challenges in existing facilities already built around different hardware communication architecture.
Modernizing an aging facility requires a well-considered plan that uses experience to balance objectives, risks and costs. Questions to consider include whether a complete retrofit is necessary, if a staged implementation makes sense and how existing equipment and its alternatives should be assessed for an upgrade. A systems integrator with the right expertise can assist in reviewing and updating project specifications with emergent technologies, providing manufacturers with a strategic plan that helps them navigate this complex decision-making process.
TREND #2: More and better data
Advanced sensors are revolutionizing data collection, providing more precise measurements, greater control resolution, and an increasing variety of data points. This wealth of information enables manufacturers to refine processes for peak efficiency and close the loop in R&D test cycles, iterating designs more rapidly. A growing selection of improved data processing and analysis tools, often incorporating artificial intelligence (AI) and machine learning, transform raw data into actionable insights. These systems can automate experimentation processes, predict maintenance needs, and provide analysis for optimizing production lines in real time.
TREND #3: Simulation models
Simulation models are a valuable tool for mitigating risk and lowering costs in automation projects. These models help manufacturers validate expected outcomes and identify design gaps where they have the greatest latitude to make the optimal performance modification for the lowest price. They also serve as a reference point for installed equipment. Building effective simulations demands both process knowledge and expertise in simulation technology. This expertise involves translating traditional engineering knowledge into sophisticated simulation models aided by complex software. Experience in simulation development helps the systems integrator determine if a simulation model would add value to a project because not all projects need them. With this in mind, finding the right systems integration partner requires careful research and vetting.
TREND #4: Heightened cybersecurity imperative
As industrial facilities become more automated, integrated and data-driven, they turn into attractive targets for cybercriminals. Dragos, an industrial cybersecurity and intelligence firm, found that of the cybersecurity alerts it analyzed in 2023, 53% could cause the loss of visibility and control over operational technology (OT) networks. This is a 51% increase over the previous year. A 2023 cyberattack on Clorox caused operational downtime, resulting in an ongoing loss of hundreds of millions of dollars due to reduced production and lost market value.
The escalating threat landscape for OT networks reinforces the need to conduct regular cybersecurity assessments for all new projects and ongoing facility maintenance to maintain a solid defensive posture. When considering an automation technology upgrade, the planned topology and architecture must be designed with security as a priority. Software and hardware are selected to achieve the required process performance at the lowest acceptable risk of cyberattack.
Front-end planning is the cornerstone of successful automation integration
Every process and application has its unique aspects, making predefined or off-the-shelf solutions inadequate for addressing any individual company’s specific needs or constraints. The vast array of available automation technologies, platforms and equipment complicates the selection process, necessitating careful planning and expert guidance before buying equipment or entering the design phase.
Starting with a front-end planning (FEP) phase is a critical step. FEP is a structured approach to defining project requirements, assessing feasibility and outlining high-level solutions before committing significant resources. An effective systems integrator facilitates a conversation with company stakehold-
FIGURE 2: Protecting hardware and software systems from cyber threats is crucial for business continuity, national security, and the integrity of vital systems like programmable logic controllers (PLCs).
Learningu
Objectives
• Understand the critical role of front-end planning and systems integrators in designing and implementing optimized automated systems in testing and manufacturing facilities.
• Identify and analyze four key automation trends—modernizing aging production lines, advanced data collection, simulation models, and heightened cybersecurity—and their impacts on process modernization.
• Learn the importance of a balanced approach to automation integration, recognizing the potential risks and benefits while avoiding inefficient and costly patchwork systems.
Demanding automation trends that make integration planning essential
FIGURE 3: A global automotive company upgraded 26 internal combustion engine test cells by replacing outdated PLC and data acquisition (DAQ) systems with new, custom-designed solutions integrated by ACS and a data acquisition supplier. Courtesy: ACS
ers to fully explore the following key considerations:
1. Current capabilities and preferences. This includes documenting existing infrastructure, preferred vendors, and equipment. An example of which is assessing whether the facility has sufficient electrical capacity to power more expansive automated systems.
2. Specific process requirements. It is essential to understand what the company needs to accomplish in its R&D or production line for a given product. This involves detailing the desired outcomes and ultimate performance metrics.
3. Process complexity. Evaluating the intricacy of the desired automation helps determine the appropriate level of technology and expertise required.
4. Comparison with existing systems. Assessing how different or similar the new process is to existing ones can inform decisions about integration and potential compatibilities.
5. Data requirements. Determining what data and data flows are needed to support design validation, process control, and maintenance is fundamental to shaping the automation strategy.
The FEP process helps organizations right-size their automation efforts, using existing technologies where appropriate and customizing solutions where necessary. It enables organizations to identify potential risks early, optimize resource allocation, and ensure alignment between automation initiatives and business objectives. FEP also provides a framework for evaluating the economic viability of different approaches, potentially saving time and money by identifying suboptimal or insufficient options before significant resources are allocated.
Harnessing FEP for strategic outcomes
FEP produces crucial documentation that serves as a powerful decision-making tool. It includes the
system integrator’s analysis of trade-offs that stakeholders can use to assess various automation design scenarios, each presenting a different balance of costs, benefits, and risks. This comprehensive evaluation enables organizations to make automation equipment and design choices, considering factors like compatibility with existing systems, integration challenges, and facility constraints.
The FEP documentation also captures historical knowledge about facilities and existing systems, ensuring critical information is preserved and used effectively. This approach prevents the ongoing risk of piecemeal equipment acquisition, where incompatible automation components might be purchased without considering how they’ll integrate. The final deliverable from any FEP study that passes the viability checkpoint can take two forms: A fully defined automation solution ready for the design phase or a compelling business case for project advancement.
A skilled systems integrator could still implement automation upgrades without the FEP process, but this ad hoc approach is more likely to fall short of optimal results. It might steer the company toward the desired outcomes for automating the process, but at a higher cost and likely without achieving the valuable outputs and potential customizations. Conducting an FEP phase builds the foundation for the seamless integration and optimal performance of automated systems within the existing facility and network infrastructure.
Balancing modernization and risk in automation
Manufacturers react differently when faced with the surge of automation technologies and potential benefits. Some adopt every new technology without assessing the integration risks or dependencies. These companies find themselves with expensive, fragmented systems that underperform. More risk-averse companies prefer not to fix what they don’t consider broken. The cost of their complacency is falling behind those organizations reaping automation’s competitive benefits.
The more balanced, measured approach lies in the middle. Manufacturers can implement automation by engaging in FEP with a systems integrator. FEP secures the design of an automated subsystem that aligns with the company’s budget, goals and constraints.
A systems integrator specialized in automation technologies ensures interoperability among vari-
Continued on pg 48
Cody P. Bann, SmartSights; Nick Becker and Scott Dappen, SCADAware
How system integrators, advanced technology help end users plan for the future
System integrators (SIs) have an important role in counseling manufacturing end-users on the benefits that advanced technology can have in helping them navigating the current challenges and plan for the future
As experienced system integrators (SIs) may know, an election year brings uncertainty to businesses as they brace for the possibility of policy changes that might affect them negatively. This uncertainty may cause companies to delay investments and reduce inventories, and may create additional risk and supply chain disruptions.
In addition to the election, the global business environment is becoming more volatile due to systemic macroeconomic and geopolitical changes. The 2024 Global Risks Report by Marsh, a business of Marsh McLennan, outlined the major trends in the current global political and economic landscape that will impact multinationals in the year ahead. The report highlighted businesses will need to strengthen their ability to identify, prepare for and mitigate difficult-to-predict challenges in the coming year.
The U.S. manufacturing industry has emerged from the pandemic on a strong growth trajectory, which is expected over the next 10 years as companies work to meet evolving customer demands, de-risk their supply chains and leverage government incentives and policies. Despite substantial growth in the sector, U.S. manufacturing faces a skills gap and tight labor market. According to a Deloitte and Manufacturing Institute study, companies need millions of workers in production and tech roles — as many as 3.8 million additional employees could be needed in manufacturing between 2024 and 2033. Additional investment in technology could be one answer to help manufacturers overcome these challenges in the short- and long-term.
Despite the continued volatility and uncertainty, there are substantial global growth opportunities that organizations may benefit from if these risks are managed.
Manufacturers have to
upgrade technology
FIGURE 1: WIN-911 software monitors each stage in Greater Austin, Texas-based Night Hawk Frozen Food’s sophisticated refrigeration process. This includes the company’s state-of-the-art refrigeration system’s cooling towers, which remove excess heat and maintain precise temperatures. Courtesy: Night Hawk Frozen Foods
Significant labor and skills gap issues, lingering supply chain challenges and the uncertainty that comes during an election year can be daunting. However, evaluating the strategic plan and shifting it with the business environment is critical to meeting goals. Two key questions leadership should ask: Did we keep up with technology? Did we invest in the right equipment?
Falling behind on technology trends can result in losing a competitive edge or not meeting customer expectations. The impact changing technology has on businesses is undeniable and a responsible investment — perhaps especially because of the current challenges — in technology can go a long way to meeting strategic long-term goals.
How system integrators, advanced technology help end users plan for the future
Objectives Learningu
• Understanding the
• Understand the unique role SIs play as honest brokers in bridging the gap between end-users’ legacy systems and smart technology, and reassure customers on the importance of leveraging the latest technologies to increase operational efficiencies, reduce unplanned downtime, lessen costs and improve cybersecurity practices.
• Learn about the skills SIs have acquired and leverage to meet clients where they are.
New technologies also can help companies streamline their processes, improve efficiency and reduce costs. Technology can also help companies stay ahead of their competitors by providing the needed tools to innovate and adapt to changing market conditions.
In The CFO Survey, a collaboration of Duke University’s Fuqua School of Business and the Federal Reserve Banks of Richmond and Atlanta, more than half of respondent firms report implementing software, equipment, and/or other technology to automate tasks previously completed by employees, which is important given the labor shortage and skills gap. The majority of manufacturers agree on the importance of smart factories and upgraded technology. In fact, in the United States, 86% of manufacturers believe smart factories will be driving the competition in the industry by 2025. Despite this, they’re still wary about making commitments.
Systems integrators can help bridge the technology gap
It’s important for integrators to acknowledge the challenges their customers face as well as help them understand the ramifications of not investing in new technology. While the initial outlay may be expen-
sive, not upgrading can be even more expensive. Reiterating the tremendous benefits of upgraded technology also will help drive home the message of increased efficiencies, improved quality control and a better working environment with a more modern facility helps retain younger workers. A modernized plant also allows companies to tap into new business models such as customization and on-demand manufacturing.
The system integrator’s understanding of hardware, software and communication protocols, as well as intuitive domain knowledge help create an automation system designed to meet the varied needs of each end user.
System integrators also can bridge the gap between legacy systems and smart technology. They also can reassure customers on the importance of leveraging the latest technologies to increase operational efficiencies, reduce unplanned downtime, lessen costs and improve cybersecurity practices.
It’s important to stay well informed on the latest compliance regulations and technology and work closely with developers to understand the hardware and software upgrades so integrators can customers the best solution.
Meeting clients where they are
While many manufacturers were undergoing a digital transformation prior to the pandemic, COVID-19 accelerated the pace and created a situation where technology and remote work were embraced. Because it proved so effective, this continued and has even become more prominent and system integrators have been at the forefront.
As a result, plant personnel, with the flip of a switch, can grant SIs remote access to every controller in the facility. Project support tools and systems are accessible through the cloud and employees work in a remote and hybrid manner.
Being flexible is a trademark of system integrators. Meeting clients where they are eliminates waste, optimizes processes and delivers value. Technology enables better collaboration in real-time and in multiple locations between integrators and clients, leading to data-centric environments.
To further meet customers’ needs, system integrators also have educated themselves on cybersecurity and the critical need to protect digital assets. This knowledge allows integrators to counsel about the many evolving challenges and help plants implement the necessary protocols to avoid cyberattacks.
FIGURE 2: Remote alarm notification software continuously monitors the alarms and provides important security updates on Night Hawk Frozen Food’s entire refrigeration system. Courtesy: Night Hawk Frozen Foods
current challenges facing the manufacturing industry.
Having a thorough understanding of alarm software and the importance of tiered messaging getting the right alarm to the right person at the right time — is another important subject system integrators often impress upon their customers. Since smart factories are made up of connected machines that generate large amounts of data, system integrators have had to gain an understanding of automated data analysis and how this helps end-users improve operational efficiencies.
Automated technology addresses challenges
The widespread adoption of robotics is revolutionizing manufacturing as tasks once performed by humans are now being automated. This results in greater efficiency, reduced errors and increased productivity and accuracy.
One example of robotics includes machine tending systems that are designed to accurately load and unload product from manufacturing machines 24/7 to improve the quality and consistency of the finished product. Automating rote tasks also frees up plant employees for higher-value work while addressing the labor shortage challenges.
Robotic palletizing systems are another way to help manufacturers increase production speed and accuracy. An automated palletizing process can handle large volumes of products without stopping, outperforming manual processes, resulting in faster production cycles, reduced lead times and increased overall output.
As businesses strive to stay competitive and meet market demands and challenges, the standardized vs. customized robotics cells decision is
FIGURE 3: The Night Hawk maintenance and engineering team can easily see the refrigeration equipment inflows and outflows status via remote view from the main office computers to closely watch temperatures, ammonium levels, and other critical metrics.
Courtesy: Night Hawk Frozen Foods
“Smart factories are made up of connected machines that generate large amounts of data.
Automated data analysis helps end-users improve operational efficiencies.“
pivotal. Standardized robotics cells are pre-engineered systems designed to address a wide range of manufacturing needs and come with predefined configurations, components, and software, offering a plug-and-play approach to automation.
Customized robotics cells are tailored to meet specific manufacturing requirements and are designed from the ground up, considering the unique needs and challenges of a particular manufacturing process. Customization also allows for greater adaptability, ensuring the cell can evolve with the changing needs of the business.
Technology reduces unplanned downtime
Equipment failure is the most common cause of downtime. According to analyst firm Aberdeen Research, downtime costs manufacturing facilities $260,000 per hour. A Deloitte industry report cited recent studies that show unplanned downtime costs industrial manufacturers an estimated $50 billion annually. One strategy to reduce unplanned downtime is with remote alarm notification software, which allows fewer people to monitor many more assets using devices that people already have such
Continued on pg. 48
Insightsu
System integrator insights
uThe uncertainty of an election year, combined with global volatility, could delay business investments, disrupt supply chains and necessitate stronger risk management strategies. uSystem integrators can play a key role in helping manufacturers upgrade technology to address labor shortages, improve efficiencies and remain competitive in a constantly-changing landscape.
Heath Stephens, P.E. and Sean Phillips, P.E., Hargrove Controls & Automation
Benefits of improving batch management solutions for advanced technology solutions
How right-sizing a batch management solution paves the pathway for advanced technology solutions and help companies realize Industry 4.0 automation.
Many digitalization tools are focused on bridging data from multiple sources such as control systems, business management systems (ERP), laboratory and quality systems (LIMS), and computerized maintenance management systems (CMMS). From these sources, users can get a more complete picture of a facility’s processes to better understand what is happening. These aggregated “data lakes” also allow companies to better leverage artificial intelligence (AI) and big data.
With these tools, users can better troubleshoot manufacturing processes, uncover logistics issues,
meet production demand in real time and better deploy maintenance personnel. Manufacturing execution systems (MES) are linking control systems to the business ERP, improving production scheduling to improve on time deliveries and reduce product inventories. Another key driver for digitalization projects is the need to make data more accessible to users throughout the organization.
By using visualization tools and communication technologies, manufacturers can deliver data to both frontline operators and back-office workers via web browser, tablets, and other mobile devices. Companies with batch processes have different data analysis needs and more complex data sets, but well implemented batch management solutions will help them reap the rewards of the Industry 4.0 revolution.
Every manufacturer can benefit from digitalization technologies. By recognizing the importance of established, proven solutions and building that foundation with the latest advancements, manufacturers are afforded opportunities for improvement, growth and efficiency.
The biggest return with digitalization advancements come from well-designed and operating core processes. Batch management systems are an example of how manufacturers can build from foundational technologies that provide flexibility to choose the right-sized solution for them.
Benefits of batch management systems
Control of batch processes requires an additional layer of programming and control beyond their continuous process cousins. Even within a single recipe, batch control often requires coordination of several sequential operations, where each step in the process depends on the correct completion of the steps prior.
Some processes will even contain parallel diverging and converging operations. When the batch control system is used to manufacture multiple products, their distinct recipes including different raw materials, equipment needs and associated parameter settings to produce each final product all must be managed.
FIGURE 1: An automation specialist verifying PanelView during site acceptance testing. All images courtesy: Hargrove Controls & Automation
In addition, the requirements to meet robust traceability documentation, adherence to ISA-88 batch control standards, and good manufacturing practice (GMP) standards add further complexity to management of the process.
Manufacturing facilities that run batch systems are more complex, and the metrics used to analyze these processes follow suit. Digitalization projects will depend on their raw data to be organized and accessible. Batch facilities that lack a good batch management system can still benefit from digitalization projects but must spend more time and resources to organize their data. If users are considering a control system upgrade or planning for a new production unit, careful consideration should be given to the batch management platform options.
With a good batch management system in place, users will be able to calculate cycle times, track raw material conversion during a reaction phase and develop fingerprints for golden batch characteristics. Digitalization tools can help analyze performance and make AI predictions and recommendations for process improvements.
The selection of the most appropriate batch control system must consider all application-specific factors, as well as the facility’s plans for future growth, which include not only production expansion but technology advancements. While there are many advanced batch control software systems available, by completing a thoughtful review of the facility’s true system requirements, a solution that best meets their needs can be identified and implemented. The best batch software solution is not always the most advanced option.
Why following the ISA-88 standard for batch control design is a best practice
The ISA-88 standard provides a well-defined and organized approach to the design and control of batch processing systems that is considered industry best practice. ISA-88 design principles should be followed regardless of whether or not compliance will be formally met.
It lays out standardized models, terminology and methodologies that result in better repeatability of process, consistency of final product, reusability of code and overall scalability and adaptability in batch processing. Formal compliance to the standard is important for regulated industries, including those that must also meet GMP requirements such as:
• Pharmaceutical
• Food and beverage
• Biotechnology
• Chemical.
Choosing the right batch control solution
With many batch control software solutions available, often including multiple add-on tiers of functionality and additional cost, it can be challenging to select the best option that addresses the needs of a particular process and facility.
Batch implementations can be categorized into tiers of batch management functionality.
TIER 1: Simple sequences/light batch. This level uses built-in basic process control system functionality and allows for the creation and execution of sequencing logic, which is essential for executing operations within a batch process. Depending on the control system platform, batch code may be written using a dedicated sequential function chart (SFC) language or using standard text, ladder logic, or function block programming. Sequences may or may not use ISA-88 design principles. This is a good solution if only light sequencing is required as it often requires no additional licensing and minimal design effort.
TIER 2: Batch management. This solution is often sold as an add-on product to the base control system functions, often on a sliding scale according to the number of batch units required. Modern platforms include compliance with the ISA-88 standard, incorporating structured process control and recipe management. This solution may require additional investment in a separate batch server. This solution often provides new, specialized interfaces for both operators and engineers to better schedule, track, and troubleshoot batches.
FIGURE 2: Automation engineers checking a piping and instrumentation diagram (P&ID).
“Batch facilities that lack a good batch management system can still benefit from digitalization projects but must spend more time and resources to organize data.“
• Understand how batch management solutions can improve advanced technology solutions.
• Learn what’s required for choosing the right batch control solution.
• Understand what considerations are needed for a custom solution.
Benefits of improving batch management solutions for advanced technology solutions
TIER 3: Advanced batch/campaign management. Advanced batch management integrates all tier 2 capabilities and is also designed to handle multiple recipes, multiple production trains and dynamic equipment selection and reservation. This level also can handle campaign management so individual batches no longer have to be scheduled by the operator. For a complex process or production facility, this level can increase a plant’s throughput by minimizing idle equipment time and batch start delays, which reduces overall process cycle time.
Seven considerations for a custom batch management solution
Since each batch process and manufacturing facility has specific needs, the software needs will also vary. The most advanced software solution is often not required to address a system’s needs. A cost-ef-
fective custom solution may be a better overall fit. Some of the factors to consider include:
1. Level of complexity that must be addressed within a recipe. Numerous sequential steps and/or forks within a process that proceed in parallel before recombination into a single step is typically best handled with functionality integrated into ISA-88 batch software.
2. Number of recipes that must be run by the control system. A process that includes managing many recipe variations may benefit from higher-tier software. However, depending on the process, sometimes the needs can be addressed with more cost efficient and custom solutions.
3. Scale of operation. Controlling processes involving multiple trains, parallel processes, and dynamic equipment allocation is best handled by higher-tier software.
4. Traceability requirements. Mid- and higher-tier software solutions often offer more comprehensive traceability features compliant with ISA-88 standards, including generation of electronic batch records showing detailed batch history information. However, alternatives to higher-tier software can also meet traceability requirements.
5. Formal ISA-88 and GMP compliance. GMP requirements demand proof of product consistency, quality, and detailed batch history records. These requirements are best met with mid- or higher-tier software that supports ISA-88 compliance and documentation capabilities.
6. Future growth plans/scalability requirements. The software selected should be suitable to address future plans for more batch processing due to production increases, if appropriate.
7. Matching the existing control system vendor. When batch control software is being selected to operate on existing equipment, it is best for compatibility reasons to use the batch control software offered by the basic process control system vendor. However, there may be certain situations (legacy control system platform, a mixed control system environment, etc.) where this is not possible. Careful planning and testing will be required in these cases.
MES and batch processes
A chemical manufacturer completed a process expansion for a facility running a PLC-controlled batch process. As part of this, they needed to update their existing MES. They had two options:
FIGURE 3: An automation engineer checking wiring during installation.
Implementing the next software tier from their programmable logic controller (PLC) vendor batch recipe management system or adapting and improving an existing custom solution. While the vendor solution offered some advantages with built-in functionality, the chemical manufacturer was concerned about some of the software limitations and the recurring annual software subscription costs.
The custom MES solution provided a better link to their ERP platform and all recipe management functionality the facility required. This provided gains in speed of the process from customer order to product shipment and alleviation of manual functions. Thanks to their well-designed batch implementation, the new MES was a success. It connected to the batch system and executed orders from the business ERP and loading recipes for dozens of products.
The batch solution foundation allowed the MES to connect the ERP with the batch process, perform as a process engineer user interface to recipe management and tie together the process and business units, resulting in a successful product expansion. With this solution, the chemical manufacturer added a new feature with dynamic parameter entry, increased maximum parameters per batch phase from 22 to 63, and developed 14 recipe management interface displays.
Visualizing and analyzing batch processes
Another manufacturer had been constrained by poor visibility and insight into their processes. Process analysis was restricted to whatever trends were available on the control system HMI and data either manually exported, or written down on log sheets. Meanwhile, personnel across the company were be-
FIGURE 4: A sample of phase logic written in S88 compliant structured sequential function chart (SFC) language.
“They were able to push data out to key performance indicator (KPI) screens on the process floor so operations could better track processes and make informed real-time decisions.“
coming more used to obtaining other business data using Power BI and web browser interfaces. Their digitalization efforts also focused on pulling data out of the control system and into more easily accessible data warehouses. Once there, process data could be delivered to anyone in the organization or even pushed into the cloud for further analysis. They were able to push data out to key performance indicator (KPI) screens on the process floor so operations could better track processes and make informed real-time decisions.
Batch manufacturing for advanced Industry 4.0 tools
The selection of the most appropriate batch control software solution relies on careful consideration of current and future application-specific requirements. AI and digitalization tools can then be implemented to further optimize performance. The combination of foundational technology and advanced solutions results in an efficient, reliable, and scalable operation that meets the distinct demands of the process and unlocks the benefits of the most advanced Industry 4.0 tools. GSIR
Heath Stephens, P.E., is a digitalization leader, and Sean Phillips, P.E. is a project manager for Hargrove Controls & Automation.
u
Insights
Batch management system insights
u Digitalization tools enhance manufacturing by bridging data from various systems, enabling better process understanding, real-time troubleshooting and AI-driven optimizations across the entire facility.
u Effective batch management, aligned with ISA-88 standards, is crucial for complex processes, ensuring consistency, scalability and compliance while facilitating integration with advanced Industry 4.0 technologies.
Dino Busalachi and Craig Duckworth, Velta Technology
How CISOs can overcome industrial cybersecurity talent, resource shortages
The industrial cybersecurity sector is grappling with a severe shortage of skilled professionals, and CISOs have to bridge this gap and the IT/OT divide.
The industrial cybersecurity landscape is facing a crippling talent crisis, as evidenced by hiring challenges and the "great resignation" of chief information security officers (CISOs) as a fallout of escalating cyber events.
CISOs responsible for the security of critical infrastructure and manufacturing organizations are grappling with immense challenges leading many to quit their roles or transition out to other areas of responsibility.
The core issue is the sheer complexity and scale of securing industrial control systems (ICS) and operational technology (OT) environments.
Unlike traditional IT networks, OT systems powering manufacturing facilities and critical infrastructure are often decades-old, decentralized and not centrally managed by the CISO's team. This makes it difficult for CISOs to gain comprehensive visibility and control over these mission-critical assets.
Without a cohesive, collaborative approach, industrial organizations remain vulnerable to cyber threats that can disrupt critical operations, damage equipment and even jeopardize worker safety.
"With the workload, the stress and responsibility without authority, you can't easily make effective change within the environment. The easiest path is out the door," said Craig Duckworth, a former CEO and co-founder at Velta Technology, highlighting the immense pressures facing CISOs tasked with bridging this IT/OT divide.
This challenging situation is compounded by a severe and worsening shortage of skilled industrial cybersecurity professionals. Securing OT environments requires a unique blend of IT, operational and domain-specific expertise — a combination that is hard to come by and takes years to develop.
"Once they recognize, or they may even know what the problem is, they're just looking for a way to shield themselves from the things they can't or don’t have the expertise to manage. Those things need to fall to somebody else," said Dino Busalachi, CTO and co-founder at Velta Technology, highlighting the limited options CISOs have in the face of this cybersecurity expertise and talent crisis.
Learningu
Objectives
• Understand the causes and consequences of the industrial cybersecurity talent shortage.
• Explore strategies to bridge the talent gap, including upskilling existing personnel, building a pipeline of specialized professionals, and ways to leverage partners.
• Learn approaches to bridge the IT/OT divide, fostering collaboration between teams to enhance overall industrial cybersecurity protection.
Adding to the problem is the rapid growth of Internet of Things (IoT) devices on the network edge, as well as the increasing sophistication of cyber threats targeting industrial operations. CISOs are overwhelmed by the scale and complexity of securing these hybrid IT/OT environments.
A major contributing factor to the security challenges is the disconnect between information technology (IT) and OT teams. While IT professionals focus on securing enterprise networks and systems, they often lack the specialized knowledge and understanding of the OT environment and its unique vulnerabilities.
However, OT personnel responsible for industrial equipment and control systems may not have the cybersecurity expertise to properly assess and mitigate risks.
This lack of communication and shared understanding between IT and OT can lead to critical blind spots as each group assumes the other is responsible for securing the overall industrial ecosystem.
The talent crunch is acute at the plant level, where CISOs often lack the resources to have dedicated cybersecurity personnel on-site. This leaves plant managers — who are focused on operational metrics rather than cybersecurity — to handle security responsibilities they are ill-equipped to manage.
"Security gets in the way of progress," Duckworth said, emphasizing the cultural and organizational challenges CISOs face in getting plant-level buy-in for security initiatives.
Eight issues stemming from the cybersecurity talent, skills shortage
Here are some of the key issues and risks associated with talent shortages and lack of experienced talent in industrial manufacturing and critical infrastructure cybersecurity:
1. Lack of visibility and control over OT/ICS assets. Without the right expertise, CISOs, plant management, and security teams struggle to gain
comprehensive understanding and control over the sprawling, legacy OT systems in manufacturing plants and critical infrastructure. Blind spots in asset inventory, vulnerabilities and access management increase the attack surface.
2. Inability to implement effective security measures. Lack of skilled personnel makes it difficult to deploy, configure, and maintain robust cybersecurity controls like network segmentation, access management, threat monitoring, and incident response. Cybersecurity initiatives often get deprioritized in favor of operational priorities and production which has often been the plant floor management’s priority.
3. Greater susceptibility to cyber-attacks. Under protected OT/ICS environments are prime targets for sophisticated threat actors looking to disrupt critical operations, steal intellectual property, or conduct destructive attacks. Successful breaches can lead to safety incidents, environmental damage, financial losses, reputational harm and even loss of human life.
4. Compliance and regulatory challenges. Adhering to industry standards and government regulations around industrial cybersecurity requires specialized knowledge that is in short supply. Noncompliance can result in hefty fines, legal liabilities and even loss of business in extreme cases.
5. Inability to keep up with evolving threats. The changing industrial cybersecurity landscape with new vulnerabilities, attack vectors, and threat actor tactics requires continuous learning and adaptation. Lack of skilled personnel limits an organization's ability to keep up with cybersecurity demands, let alone stay ahead of the curve.
6. Operational disruptions and downtime. Security incidents can impact the availability and reliability of industrial systems, leading to expensive
production delays and operational disruptions. Recovering from cyber-attacks requires specialized expertise that may not be available and lead to greater risks and losses.
7. Ineffective incident response and recovery. Without experienced incident response teams, organizations struggle to contain the impact of breaches, conduct thorough investigations, and implement robust recovery plans. Delayed or improper response can exacerbate the damage and prolong downtime.
8. Vendor/supplier risk management challenges. Securing the broader industrial ecosystem, including third-party vendors and suppliers, requires specialized knowledge of OT/ICS environments, equipment, and processes. This lack of expertise makes it difficult to assess and mitigate risks introduced by interconnected systems and supply chain relationships.
Addressing these challenges requires a multipronged approach focused on building a strong pipeline of industrial cybersecurity talent, upskilling existing personnel, and fostering a culture of security within manufacturing and critical infrastructure organizations.
Bridging the IT/OT divide and aligning these traditionally siloed teams is essential to enable comprehensive industrial cybersecurity across manufacturing and critical infrastructure organizations.
Tackling the talent shortage, improving IT/OT collaboration and shifting the organizational mindset to collaboration will help industrial organizations overcome the immense cybersecurity challenges facing CISOs, operations, manufacturing teams and their organization as a whole. GSIR
Dino Busalachi is CTO and co-founder of Velta Technology; Craig Duckworth is a former CEO and co-founder of Velta Technology.
Management visits an industrial environment, emphasizing the importance of bridging gaps between different organizational levels and areas of expertise for effective operations and security. Courtesy: Velta Technology
Insightsu
Cybersecurity Insights
u Chief industrial security officers (CISOs) in industrial sectors are overwhelmed by the complexity of securing operational technology (OT) systems, which often lack centralized management, exacerbating visibility and control issues.
u The growing disconnect between information technology (IT) and OT teams, compounded by a severe talent shortage, leaves industrial organizations vulnerable to cyber threats, operational disruptions and compliance challenges.
Jason Markesino and Chris Gomez, Applied Manufacturing Technologies (AMT)
How integrating an AMR can provide value in manufacturing, industrial facilities
Experienced autonomous mobile robot (AMR) system designers can help a facility integrate innovative and cost-efficient solutions that address many challenges in manufacturing and industrial facilities.
Learningu
Objectives
• Understand key technology advancements with autonomous mobile robots (AMRs).
• Learn what’s needed for the integration of an AMR fleet.
• Learn how to connect the AMR fleet to the industrial control system (ICS).
An autonomous mobile robot (AMR) is a type of industrial mobile robot (IMR) designed to move freely throughout a facility, completing tasks without the need for fixed pathways or regular human guidance. Equipped with several sensing technologies and onboard intelligence systems, AMRs now have the information and processing power to sense, interpret and navigate through dynamic environments. Light detection and ranging (LiDAR) systems, cameras, vision systems, pressure sensors, encoders, inertial measurement units (IMUs) and even ultrasonic and infrared sensors collect information about the current environment as well as the AMR’s motion within it. This information is then analyzed using data processing algorithms including different types of artificial intelligence to create a map of the AMR’s surround-
ings, allowing it to plan routes and make decisions for obstacle avoidance.
Further expanding its capabilities, AMRs can now be outfitted with a top-mounted robot, called a mobile manipulator. AMRs come with a variety of payloads, ranging from 250 kg to more than 1350 kg. As an example, AMT has worked with manufacturers in the automotive industry to move heavy pallets of engine transmissions using larger AMRs. These include high-payload AMRs that can be coordinated for simultaneous movement of bulky and heavy parts such as an airplane fuselage in the aerospace industry. When using a mobile manipulator, the effective payload may be decreased depending on the location and orientation of the weight.
With guidance from an experienced integrator, a fleet of AMRs can be commissioned in a few days’ time for wide-ranging applications, including material handling, machine tending, sortation and more with minimal downtime.
Five
key technology advancements in
AMRs
The growth of AMR use cases is driven by the maturation of key technologies. Five of the biggest are highlighted.
1. Simultaneous localization and mapping (SLAM) technology
Perhaps the most important recent advancement, the maturation of SLAM technology has increased AMR capability and ease of implementation and commissioning. SLAM technology uses a variety of sensors, including LiDAR, cameras and IMUs to gather information and create a map of the current environment.
The AMR detects fixed points such as walls and posts to accurately localize its position. This information allows SLAM to determine the AMR's current position and motion within the environment. SLAM enables the AMR to interpret, map and navigate its surroundings.
2. Artificial intelligence (AI) and machine learning (ML)
AI and ML algorithms allow the AMR to analyze the large amounts of environmental data collected
FIGURE 1: MiR's fleet manager software, illustrating advanced navigation and fleet coordination for autonomous mobile robots. Images courtesy: Applied Manufacturing
“An AMR fleet can be commissioned in a few days for applications including material handling, machine tending, sortation and others with minimal downtime.“
by its sensors to make informed decisions regarding navigation and operations. Some types of AI now integrated into AMR technology include:
• Machine learning analyzes patterns in sensor data, allowing the AMR to learn from previous operations. For example, an AMR will learn the most efficient paths and times to perform an activity based on past experiences.
• Machine vision is used in object recognition, which allows the AMR to use visual information for navigation and task completion. Machine vision interprets data from cameras to identify paths, obstacles and previously known markers. Deep learning has become a primary approach to machine vision because of its ability to detect patterns within an image. In the context of AMRs, this technology facilitates object detection, image classification and even facial recognition.
3. Collaborative robots (Cobots)
The integration of AMRs with a cobot (known as a “mobile manipulator”), which is designed to safely operate within human proximity, expands the potential tasks an AMR can complete. For example, depending on cycle time requirements, an AMR with a top-mounted cobot can perform many tasks at different stations. This allows for greater flexibility as the automation is not fixed in place.
4. Battery technology
AMRs benefit from the energy improvements offered by lithium-ion (Li-ion) battery technology. These benefits, including high energy density, longer lifespan, and fast charging times, enable AMRs to operate for 8 to 12 hours on a single charge, although this timeframe is application dependent. Newer AMR models with advanced battery technology can operate for 15 to 20 hours between charges. Some AMRs also support fast charging technology, further enhancing their operational efficiency.
5. Onboard computing
Improvements in processing power enable the AMR to perform the complex computations locally which are necessary for its decision making for navigation and operations. This edge computing capability reduces the latency associated with data processing compared to centralized or cloud-based computation. The result is improved robot reaction times and more effective real-time decision making.
Because of AMRs’ flexibility and ease of implementation, they can displace several traditional manufacturing and logistics systems and tasks across multiple industries.
How AMRs are a safer alternative to forklifts
Due to their extensive environmental sensors and safety features, AMRs are safer in high-traffic environments compared to traditional operator forklifts. Many industrial facilities, including manufacturing plants, warehousing and logistics centers, distribution centers and processing plants have chosen to implement a fleet of AMRs for material handling in high human traffic environments. As a result, forklifts have been redeployed to the more segregated areas of the facility for dock loading and unloading tasks.
Six ways AMRs can replace conveyors
Another interesting application gaining significant traction within industrial settings involves using AMRs to replace traditional conveyors. While conveyors remain the stronger choice for high volume, high-speed, fixed-path continuous flow applica-
FIGURE 2: An engineer supervises the operation of MiR's autonomous mobile robot, designed for efficient material handling in industrial environments.
How integrating an
AMR
can provide value in manufacturing, industrial facilities
tions, AMRs excel when flexibility, dynamic routing and adaptability to multiple tasks is preferred or required. The advantages of using AMRs for this purpose include:
1. Less floor space: AMRs do not require dedicated floor space like conveyors.
2. Non-fixed installation: AMR implementation requires minimal infrastructure change.
3. Ease of scalability: When more throughput is needed, adding additional AMRs is generally easier than expanding a conveyor system. The program developed for one AMR can usually be duplicated into others.
4. Adaptability and flexibility: AMRs do not require dedicated, fixed pathways. Using SLAM technology, they dynamically and autonomously adapt to layout changes. This can be particularly helpful in fulfillment centers, where product locations and volumes may change. AMRs can be reprogrammed for new routes and tasks very quickly without physical infrastructure changes.
5. Potential for lower initial investment: Compared to traditional conveyors, implementing AMRs can be cost competitive. This is particularly relevant for complex paths that may be in manufacturing facilities with varying production processes requiring material transport between production cells.
6. Versatility: AMRs can take on more than just basic transportation tasks; they are also capable of tending machine centers and performing picking, placing and sorting tasks.
Five things to consider when integrating an AMR fleet
Important aspects and potential limitations to consider in AMR system design include:
1. AMRs take up a larger area than expected once the safety field surrounding the base unit is considered. As a result, smaller areas are inherently difficult to navigate and necessitate a targeted solution.
2. When choosing the size of fleet to be implemented, consider the frequency of missions, the distance the AMRs will cover and the overall mission cycle time. The size of the fleet will also be dependent on the ability to meet the Wi-Fi network port availability, speed, and bandwidth requirements.
3. A robust automated system requires wellplanned error state recovery. Some common errors to consider include an AMR that is unable to get to its destination and an AMR stopped in the middle of a mission.
4. Current challenges to AMR operation include environmental temperature and humidity changes that result in condensation on the optical components. Direct sunlight also can interfere with their safety scanners. The floor surface is also critical: Concrete works well, carpet is less suitable and wet floors can cause slippage, which can interfere with the wheel rotation counts used to track displacement, leading to positioning errors.
5. When implementing an AMR fleet, additional program design is needed to ensure they don’t trap themselves in an area. One way to handle this error state is by setting up traffic zones, allowing only one AMR into a given zone at a time.
AMRs require expertise for full integration
Another challenge to AMR implementation involves their integration with other automation control systems, including programmable logic controllers (PLCs). Most PLCs cannot directly initiate missions for AMRs, which means an intermediary system is required to facilitate communication between them.
Fleet manager software coordinates the operations of multiple AMRs within a facility. Using an application programming interface (API) calls for communication between the AMR fleet manager software and associated AMRs, as well as for incoming requests to the fleet manager from other control systems. However, due to their focus on real-time industrial communication, most PLC brands are not able to generate web-based communication such as an API call.
FIGURE 3: OTTO Motors' autonomous mobile robot efficiently transports stacks of yellow bins, streamlining material handling processes in an industrial setting.
FIGURE 4: Engineers collaborate using OTTO Motors' autonomous mobile robot in a warehouse setting, highlighting the integration of advanced robotics into industrial workflows.
One way to solve this problem is using a middleware software platform that connects to the PLCs via industrial protocols and Python scripts that generate the associated API calls to communicate with the AMR fleet manager.
Using an example case of a PLC requesting more parts, the AMR system operates as follows:
• The PLC monitors production processes. When it detects a need for more parts, it communicates with the software using standard protocols (i.e. OPC UA)
• The software detects the tag change and using a python script translates the request for more parts into an API call.
• The API call is sent to the fleet manager and may include details about the type and quantity of parts needed and the timeline.
• The fleet manager selects the best AMR to deploy for the task. For each AMR, it may consider its current workload status, relative proximity to the target work environment, and even current battery status.
• The fleet manager generates an API call to communicate with the target AMR to dispatch it for the task. The call will include details of the operation, including location of pickup and drop-off.
• The AMR obtains the additional parts and delivers them to the requesting PLC’s production line at the drop-off location.
“A robust automated system requires well-planned error state recovery. Common AMR errors include inability to get to its destination and stopping in the middle of a mission.“
The value of working with an experienced integrator for AMR implementation cannot be overstated. An experienced integrator understands PLC and AMR communications and knows how to use middleware software as an intermediary, allowing them to effectively integrate an AMR system with existing automation technology.
The growth of AMRs for solving common manufacturing challenges has been driven by key advancements in sensing technologies and data processing capabilities. These advancements have increased the breadth and complexity of tasks AMRs can now complete while simplifying their implementation. Working with an experienced integrator, an AMR solution can be designed and implemented quickly with minimal on-site downtime. Experienced integrators can help manufacturers address remaining AMR integration challenges, positioning them for rapid adoption of this flexible and scalable solution. GSIR
Jason Markesino is an innovation manager and Chris Gomez is a lead automation engineering for Applied Manufacturing Technologies (AMT).
Insightsu
Autonomous mobile robot (AMR) insights
u Technology advances empower autonomous mobile robots (AMRs) to accurately map and navigate environments, boosting their adaptability and ease of deployment across dynamic industrial settings.
u Artificial intelligence (AI) and machine learning (ML) enhance AMRs by enabling real-time decision-making and efficient operations, learning optimal paths and improving object recognition through advanced machine vision.
u Battery advancements in AMRs operational hours and efficiency, ensuring consistent performance in demanding industrial environments with minimal downtime.
Demanding automation trends that make integration planning essential
FIGURE 4: Designing R&D testing facilities "from the inside out" prioritizes testing criteria and capabilities, ensuring that facility integration and design align with testing requirements and product goals. Courtesy: ACS
Continued from pg. 34
ous systems and facility infrastructure. The result is a system that unlocks automation’s full potential for streamlined processes, enhanced innovation and quality, and profitability. GSIR
Andrew Harris is director of business development, instrumentation and controls; Matt Thiel is director of facility planning and integration for ACS.
Insightsu
Automation and system integration insights
u Automation enhances efficiency and safety in manufacturing, but its complexity necessitates strategic planning. A skilled systems integrator is key to maximizing automation's full potential and benefits.
u Modernizing outdated production lines requires adopting flexible technologies like AMRs and cobots. A systems integrator can guide manufacturers through upgrading while minimizing risks and costs. Front-end planning helps.
How system integrators, advanced technology help end users plan for the future
Continued from pg. 37
as smartphones and tablets. Uninterrupted remote availability is essential to ensuring systems can be continuously monitored, even without staff onsite or with fewer people working at the facility.
Remote monitoring of critical plant systems has been extended beyond email, texts and phone calls to include apps that feature time-saving tools like real-time alarm acknowledgements, team chats to troubleshoot and resolve plant problems, and detailed reporting for preventing future incidents. Not only does this mean fewer emergency shutdowns, but also fewer resources spent on overtime and maintenance.
A mobile alarm notification app is software that integrates with the supervisory control and data acquisition (SCADA) or human-machine interface (HMI) software of an industrial operation, allowing an employee to monitor, receive and acknowledge plant and machine alarms on their smartphones or tablet, freeing them up to work throughout the facility or a remote location.
Hardware and software are available that can monitor equipment and, by applying machine
learning to historical data, warn when a breakdown or other problem is imminent. Bolstered by wireless technology and the industrial Internet of Things (IIoT), these customizable systems have the potential to bring predictive maintenance to a new level. Through the installation of remote alarm notification software, manufacturers can move to a more prescriptive maintenance approach rather than a reactionary one.
SIs play a unique role
SIs play an important role as brokers in the process of helping clients navigate uncertain times by listening to their challenges and recommending solutions. The unique expertise brought by a skilled controls system integrator provides an invaluable link between operations teams and IT vendors who offer solutions for operations — like remote alarm notification software — and clients. GSIR
Cody P. Bann is director of engineering at SmartSights; Nick Becker is vice president of SCADAware; Scott Dappen is vice president of engineered solutions at SCADAware.
FIGURE 4: Robotic palletizing systems are one way to help manufacturers increase production speed and accuracy. Courtesy: SCADAware
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• cUL Listed & Recognized versions
• NEMA Ratings: (12, 4, and 4X)
Software Toolbox has reduced risk for System Integrators since 1996. We reduce risks associated with the use of third party or add-on software to major HMI/SCADA/MES packages, and the risks of writing custom software to meet a specific need. The software products we provide involve applications in reporting, data collection, device integration, remote data connectivity, logging, visualization, OEE, SCADA, cloud services, and more are used in all industrial verticals and are trusted by users in over 110 countries.
Collaboration is what the Software Toolbox experience is about.
Our clients benefit from this culture that loves working together; committed to reliability and responsiveness. Thousands of integrators and users around the world experience our knowledge of how industrial software can work together through our ability to work patiently with multiple vendors and customers.
Visit us at info.softwaretoolbox.com/integrators to learn more.
Our risk reduction formula is equal parts of providing a variety of off-the-shelf software products, combined with the knowledge of how they work with major supplier’s software products or together on their own, to solve real manufacturing operations challenges, and back it with support that, well, you just have to experience the difference.
John Weber Partner Program Manager
Software Toolbox Inc.
Email: jweber@softwaretoolbox.com
Telephone: 704-849-2773
Charlotte, NC
SYSTEM INTEGRATORS SPONSORED BY SOFTWARE TOOLBOX
System Integrator Corporate Close-Ups
GLOBAL
INTEGRATION EXPERTISE CREATES SUSTAINABLE VALUE
With over 40 years of industrial experience, Actemium’s global integrator network is equipped to meet the technology and support needs of any size manufacturer, anywhere. Actemium in North America provides services in industrial IT/OT, digital transformation (DX), and Industry 4.0 services plus MES and data analytics.
Wilfred Misener, Director of Business Development, North America
• Wilfred.misener@actemium.com (902) 293-4393 mobile
Industry 4.0: Actemium envisions augmented reality, robots, cobots, and automated guided vehicles as key players in the Industry 4.0 landscape. Instead of deploying costly systems without clear objectives or a roadmap, Actemium consultants guide manufacturers to consider their desired outcomes and then develop the necessary solutions to achieve them.
Actemium divides their Green Initiatives into three pillars: circular economy, energy efficiency, and low-carbon solutions.
Circular Economy: Actemium provides solutions for extending equipment life by reducing and reusing electronic waste.
Energy Efficiency: Actemium enhances energy performance through process automation, digitalization, low-power high-efficiency equipment, leak detection, heat recovery, Maintenance 5.0, energy audits, and systemic analyses.
Low-Carbon Solutions: Actemium aids in the decarbonization of industrial activities by implementing renewable energy solutions.
Why Actemium? Actemium understands both current and legacy processes, how installations function, and their interconnections. With expertise in data, statistics, and machine learning, we balance technology with human elements, considering the impact of new systems. Clients choose Actemium because we ensure that systems are judged by how well their people understand, embrace, and utilize them.
We provide these services across a wide variety of industries:
As a leading system integrator, Hargrove Controls & Automation is one of few multidiscipline automation groups in the country capable of providing turnkey solutions for plant automation, safety systems, cybersecurity/OT, and industrial digitalization. Our system integration Team provides simplified solutions for our clients by working handin-hand with the engineering and execution Team throughout the project life cycle.
Our Team specializes in DCS/PLC/SIS system integration & migration, digitalization, and process safety. We can implement the vision of Industry 4.0 through digitalization such as AI-enabled advanced process control, equipment failure predictions, reliability and availability analyses, and multi-variate analysis. Our Process Safety Team of TÜV Rheinland Functional Safety Engineers has many years of experience in all phases of the process safety lifecycle including Process Hazard Analysis, SIL Calculations, Safety Requirement Specifications, and SIS logic solver programming. We provide process safety training courses, and we host TÜV Rheinland certification courses facilitated by authorized providers.
and SIS solver
Hargrove Controls & Automation implements control systems for pulp & paper, petroleum & chemical, heavy manufacturing, and other industrial facilities. Our Team consists of process control engineers and specialists, certified process safety engineers, cybersecurity professionals, networking specialists, instrumentation designers, and panel builders. We foster a culture of safety that cultivates quality throughout the project lifecycle while leveraging industry best practices. Based on your needs, our Team will operate as an independent system integrator or with the full complement of our global EPC firm, Hargrove Engineers & Constructors and our asset life cycle management company, Tormod.
Together, Hargrove and Tormod offer clients a differentiator in the marketplace by providing a complete solution for total asset life cycle management including engineering, automation, full-service EPC, maintenance, reliability, commissioning & startup, and technical services. Tormod specializes in transitioning engineered facilities into operating assets with both short-term commissioning assistance and longterm operations contracts. The success of our Team of companies stems from cultivating the most talented engineering and construction professionals while valuing long-term client relationships.
For more information about Hargrove Control & Automation, please visit https://hargrove-ca.com . For more information about Tormod, please visit https://tormod.com/.
Capabilities
• System Integration
• System Migration
Corporate Headquarters
Mobile, Alabama / 251.476.0605
KEY EXECUTIVE
Karen Griffin, Vice President Hargrove Controls & Automation
OPERATIONAL STRATEGY. THOUGHT LEADERSHIP. PROVEN & SUSTAINABLE SOLUTIONS.
A global leader in automation and information solutions since 1989, RoviSys partners with businesses to improve efficiency, sustainability and profitability. With expertise across process automation, control systems integration, building automation, MES, Industrial AI, and digital transformation, RoviSys consistently delivers proven solutions with measurable results and clear ROI.
AUTOMATION
Reliably. Effectively.
Our teams of experts and engineers are always exploring ways to meet the evolving needs of industry. We are a trusted partner for businesses worldwide, offering services from project identification and scope definition to large-scale project execution.
We're committed to innovation and helping clients stay competitive in today’s quickly-evolving environment.
Engineering Offices:
• North America: Ohio, North Carolina, Texas, Michigan, Illinois, Massachusetts, California, Georgia, Virginia
• Asia-Pacific: Singapore, Taiwan, Indonesia, Malaysia, Japan
• Europe: Nederland, Ireland
Capabilities:
• Process Automation
• Building Automation
• Discrete Manufacturing Automation
• Warehouse Automation
Primary Industries:
• Aerospace
• Automotive
• Beauty & Personal Care
• Chemicals
• Consumer Goods
• Data Centers
• Control Systems Integration
• Manufacturing Execution Systems (MES)
• Industrial Network Solutions
• Building Management Systems
• District Energy & Microgrids
• EV & Battery
• Federal Solutions
• Glass
• Life Sciences
• Mining & Metals
Whether it's a small budget effort or a massive multi-discipline, multi-site digital transformation initiative, RoviSys positions every project for success with a unique combination of project management, platform & technology experience, and vendor independence.
• Electrical Power Management Systems
• Electrical & Instrumentation Design
• Industrial AI
• Consulting
• Oil & Gas
• Paper & Wood
• Semiconductor
• Water/Wastewater
The RoviSys Company Dick CiammaichellaBusiness Development Director dick.ciammaichella@rovisys.com 330.995.8600 • rovisys.com
WE APPLY DOMAIN KNOWLEDGE AND FUNDAMENTAL SCIENCE TO MINIMIZE VARIANCE AND MAXIMIZE RESULT
Adaptive provides a range of solutions and a unique combination of technology and expertise for managing processes. More than systems integrators or software engineers, we provide the consulting and design services to minimize process variability and yield better quality and less power usage or waste.
Since 1992, Adaptive Resources has applied scientific principle to advance process control. From their Quick Study suite of advanced control technology solutions to process consulting, systems integration, Adaptive has always focused on delivering the information and tools needed to manage the most complex manufacturing processes.
Core competencies
• Quick Study APC Advanced Process Controls software suite (MPC)
• Systems Integration
• Machine Vision and Robotics
• UL 508 Industrial Control Panel Fabrication
Strategic Partnerships
• ABB Robotics
• B&R
• Cognex Partner SI
• Datalogic
• Denso Robotics
• Festo
• Keyence
• Microscan SI
• Rockwell Automation Recognized SI
• Siemens Solution Provider
• Universal Robots
Full Profile at www.cfemedia.com/systemintegrator/adaptiveresources
The state of the SI industry remains strong
I do not have time for fads
Integrated into one or more processes
FIGURE 3: Engagement by SIs with AI for internal processes. CSIA EZ-Stats, 2024-04-08. Clouds on the Horizon? Courtesy: CSIA
Control System Integrators Association (CSIA)
Continued from pg. 6
its optional certification program, it provides an objective framework to help SIs set up and improve their companies. Since its founding CSIA has witnessed significant changes in the SI landscape. Through its annual conference, webinars, podcasts and community of peers, it helps SIs stay engaged and up to date.
State of the SI industry
The state of the SI industry remains strong, and all drivers position this industry to remain strong in the years to come. Nothing is certain, and things can change very quickly (e.g., COVID-19). The SI landscape is changing, and consolidation is in full swing. SIs are becoming creative in their approaches to hiring and this will become a real differentiator. There may be a few clouds on the horizon, but SIs have weathered them well and will do so again when the need arises. GSIR
Jose M. Rivera is the CEO of the Control System Integrators Association (CSIA).
System Integrator Corporate Close-Ups
+43 316 6902 0 automation@andritz.com andritz.com
Primary Industries
• Pulp and Paper
• Mining & Mineral Processing
• Hydro
• Seperation
• Process Equipment Automation & Optimization
• ANDRITZ operates over 280 sites worldwide. Please obtain contact details of our global locations online.
• Headquartered in Graz, Austria, founded in 1852.
ANDRITZ SUPPLIES AUTOMATION AND DIGITALIZATION CONTROL SYSTEMS FOR EVERY STAGE OF YOUR PLANT PROCESS.
ANDRITZ is a globally leading supplier of plants, equipment, and services for hydropower stations, pulp and paper, metalworking and steel industries, mining, and solid/liquid separation in the municipal and industrial sectors, as well as for animal feed and biomass pelleting.
ANDRITZ Pulp & Paper: Continuous research and development activities focus on supporting customers to achieve sustainable production with higher capacities and higher energy efficiency while minimizing the consumption of energy, chemicals, and water.
ANDRITZ Hydro: A global supplier of electromechanical systems and services (“from water-to-wire“) for hydropower plants and one of the leaders in the world market for hydraulic power generation. More than 180 years of accumulated experience in turbine design. Over 31,900 turbines (more than 471,000 MW) installed globally. Over 125 years of experience in electrical equipment.
ANDRITZ Automation & Digitalization is a leading supplier of machine and plant control systems with 110 company locations worldwide. ANDRITZ provides automation services and tools for a wide range of process industries, including pulp and paper, mining, lime and cement, power, and oil and gas. ANDRITZ automation defines electrical system capacity and utility requirements, establishes an equipment numbering system, works with process engineers to accurately assign control devices to process equipment, and produces effective E&I construction and maintenance packages. As a technology leader with extensive and long-term experience in supplying industrial measurement, control, and optimization solutions for various industries, ANDRITZ is combining its process and equipment expertise with the latest advancements in the digital era. The result of this powerful combination is Metris: a portfolio of ANDRITZ Digital Solutions.
Full Profile at www.cfemedia.com/systemintegrator/ANDRITZ
CUSTOM CONTROLS
TECHNOLOGY, INC.
Gerry Gallo
Hialeah, FL 33016
Telephone: 305) 805-3700
Fax: 305-818-5976
https://cct-inc.com
Primary Industries
• Pumping Systems
• Baggage & Handling
• Industrial Automation
• Oil & Gas
• Power Generation
Other Office Locations
• Central and South America
WE ARE PRESENTING OUR NEW PRODUCT A SUBMERSIBLE ENCLOSED CONTROL PANEL FOR PUMP STATIONS AKA LIFT STATIONS.
Fully energized and functioning. This Submersible Control Panel is patented and UL Verified for No water ingress after 30 days, 12.625" above the enclosure for the CK474 model and 13"inches above the enclosure for the W8404 Model. By taking into account the following, 24" slab + 16" above the slab mounted on feet or on a Rack, the best scenario CK474 at 58" high, + 12.65" UL requirement equal 110.625" or 9.2ft). UL verification for this product is V986660 for No Water Ingress after 30 days, giving you more confidence when installing this control panel. This is the perfect solution for flood prone areas. Although this panel is not intended to work indefinitely under water, it is designed to have a resilience to flood conditions. CCT recently has tested the panel for recertification for 25 days and then continued under UL verification process and additional 30 days, under water. Which yield a complete success. Seventeen of our customized enclosure have been installed at City of Coral Gables, FL where flooding can occur during major storms.
Currently we are completing an order for LEE County Utilities for 99 units, replacing the recent devastation that occurred over more than a year ago.
Having the water pump control system working during the heavy rain fall is critical to minimizing the flooding. Our application can keep the system dry and intact during the catastrophic situations, protecting valuable assets and a quicker recovery for the municipality.
CCT is a UL 508A, UL 698A and pending UL 1741 certified panel shop and proud supporter of the Buy American Act. Please call or email us if you have any questions. Implementing New technology with 100% of Customer’s satisfaction. We are here to Serve You!
Full Profile at www.cfemedia.com/systemintegrator/customcontrolstech
System Integrator Corporate Close-Ups
(812) 479-5170
Evansville, IN
www.ecssolutions.com info@ecssolutions.com
Primary Industries
• Chemical
• Beverage & Distilleries
• Food & Bakery
• Life Science
• Metals
Other Office Locations
• Atlanta, GA
• Bowling Green, KY
• Hattiesburg, MS
• Henderson, KY
• Joplin, MO
• Knoxville, TN
• Lexington, KY
• Phoenix, AZ
• Raleigh, NC
• Venice, FL International:
• Colombia
www.etechgroup.com
Telephone: 855-202-1444
Headquarters: 8614 Jacquemin Dr, West Chester Township, OH 45069
Primary Industries
• Life Sciences
• Mission Critical
• Food and Bev/CPG
• Manufacturing
• Material Handling
Other office locations
• Alabama
• California
• Indiana
• Michigan
• New Hampshire
• New York
• North Carolina
• Ohio
• South Carolina
• Texas
• Mexico and Canada
ECS Solutions
BATCH AUTOMATION EXPERTS FOCUSED ON YOUR PLANT MANUFACTURING ECOSYSTEM
ECS is dedicated to performance improvement and innovation in batch manufacturing. Our vision of steady, sustainable growth with a diverse customer base is the foundation for making ECS a good place to work. ECS is a recognized leader in the delivery of process control systems, having achieved that status by aggressively pursuing solutions that provide the information and controls our customers need to manufacture more products faster and at a lower cost. We understand that rapid developments in technology necessitate new approaches to control systems – approaches that allow people to filter and consume information more quickly so they can make the best decisions and take immediate action to follow those decisions through. Our leadership team is focused on adding value to our customers’ process and ultimately improving their bottom line.
ECS operates under the guiding principles of excellence in all we undertake, measured internally by profitability and externally by satisfying requirements, and trust that we earn by demonstrating integrity and technical prowess, that we extend to those who prove trustworthy, and that we maintain through communication. ECS’ core values are instilled in every employee to consist communicate candidly, build trusting relationships, serve others well by being responsive, lead with the courage to take risks, continuously improve in response to changing markets and technologies, disarm conflict by handling it one on one, seek excellence rather than perfection to meet the objective, and make ECS a better place to work by being trusting and trustworthy.
E Tech Group
BEYOND AUTOMATION AND CONTROL
E Tech Group is one of the largest automation and system integration firms in the United States. With locations throughout the United States, Canada and Mexico and with over 450 engineers, we provide automation, control and information solutions to the Life Sciences, Mission Critical, Food and Beverage, Consumer Products, Metals industries and more.
We’re the Main Automation Partner to our clients, assessing where they are in their automation and digital transformation journey, developing a strategy for remediation and optimization, connecting the shop floor with the c-suite via business intelligence and data analytics, and providing ongoing maintenance and support.
Our scale allows us to help our clients develop and implement standardized solutions at any of their facilities regardless of physical location. We have the capability to bring together large teams of diverse professionals to provide turnkey projects, as well as offer professional project and program management, procurement, panel builds, site and subcontractor supervision, installation and commissioning services, and more.
Our mission is to disrupt and evolve the world of industrial automation. Our purpose is to free people to achieve the full potential of human creativity and innovation. Our clients are doing amazing things. We guide and enable them to advance their missions using the next generation of technology and human interaction.
Let’s talk.
Full Profile at www.cfemedia.com/systemintegrator/etechgroup
System Integrator Corporate Close-Ups
Kimberly Pelkey
Wilson, NC
Telephone: (252) 237-3399
kpelkey@ias-nc.com www.ias-nc.com
Primary Industries
• Automotive
• Chemical Film & Plastics
• Consumer Goods
• Energy & Utilities
• Food & Beverage
• Life Science
• Metals & Mining
• Nonwoven & Fibers
• Semiconductor
• Tire & Rubber
• Wire and Cable
• Wood & Paper
Other Office Locations
• Cedar Point, NC
• Garner, NC
• Lucama, NC
• Rocky Mount, NC
Malisko Engineering, Inc. malisko.com info@malisko.com (314) 621-2921
St. Louis, MO
Primary Industries
• Food & Beverage
• Dairy
• Consumer Packaged Goods
• Life Sciences
• Metal, Mining, & Cement
Other Office Locations
• Denver, CO
• Eau Claire, WI
Industrial Automated Systems
IAS IS YOUR TRUSTED PARTNER IN PROJECT MANAGEMENT, CONTINUOUS IMPROVEMENT, AND AUTOMATION ENGINEERING
IAS is an independent, turnkey automation provider improving quality and productivity for our global customers through innovative engineering and technology. A strategic partner for project management, system integration, and continuous improvement.
Statistical Process Control (SPC) Partners / Affiliates
• Rockwell Automation Silver System Integrator
• OSI Pi • Certified Siemens Solutions Partner • Ignition Certified
Aveva Wonderware
Full Profile at www.cfemedia.com/systemintegrator/industrialautomatedsystems
Malisko
CONNECTING PEOPLE, PROCESS AND TECHNOLOGY.
For nearly 30 years, we have connected people, process, and technology to improve manufacturing productivity and efficiency. Our team of engineers, designers, programmers, automation, and network & security specialists listen to understand your needs and develop personalized solutions. When you work with us, you’re not just investing in process automation. You’re investing in a business partnership with a group of dedicated, multi-disciplined efficiency professionals.
Malisko offers a full suite of services that work well independently or together. Our foundation in Industrial Control Systems brings practical OT experience and perspectives to Digital Transformation and Industry 4.0 initiatives.
IT/OT Convergence
We have the unique ability to bridge the gap between IT and OT with our Industrial Network, Security, and Information Specialists. Our specialists have instant credibility with both sides based on practical experience.
Plant Floor Control & Process Automation Solutions
We have nearly three decades helping manufacturers streamline their process by integrating various technologies and components to enhance efficiency, productivity, and data accuracy on the plant floor.
Manufacturing Intelligence
We help manufacturers harness the power of manufacturing intelligence by collecting, analyzing, and utilizing data to optimize processes, reduce costs, and improve overall performance in a customized and sustainable manner.
Full Profile at www.cfemedia.com/systemintegrator/malisko
System Integrator Corporate Close-Ups
Kevin Overmyer, MBA, Director of Client Solutions & Success Maumee, OH matrix@matrixti.com 419-897-5630 www.matrixti.com
Markets We Know
• Food & Beverage
• Feed/Grains/Oilseed
• Wine & Spirits
• Life Sciences
• Consumer Products
• Specialty Chemical
• Oil/Gas/Refining
• Metals
Office Locations
• Atlanta, GA
• Cincinnati, OH
• Denver, CO
• Indianapolis, IN
• Kansas City, KS
• Maumee, OH
• Minneapolis, MN
Primary Industries
• Food and Beverage
• Entertainment
• Transportation
• Life Sciences
• Manufacturing Pacific Blue Engineering info@pacificblueengineering.com www.pacificblueengineering.com (657) 201-8603
Office Locations
• Long Beach, CA
• Orange, CA
• Orlando, FL
Matrix Technologies
“GO BEYOND AUTOMATION – YOUR SINGLE SOURCE SOLUTION”
Matrix Technologies, Inc. is your single-source partner for Engineering, Construction, Automation, and Information project needs. 85% of our projects are repeat engagements successfully delivered to our satisfied clients.
• Engineering and Project Consulting
– Pre-Engineering for capital project scope and cost development
– 3D Facility and Process Laser scanning for baseline/ ground penetrating radar
–Automation Master Planning
–Digital transformation
–Network Investigation and Design
–Cyber Security
–MFG. Transformation Assessement
– Arc Flash
–Machine Safety
• Detailed Engineering
–Facility Design
–Process Conceptual and Detailed Design
–Network Design
–Mechanical and Piping Design
–Virtualized Server Systems
–Electrical Distribution and Control
–Process Automation
–Manufacturing Intelligence/MES Systems
–Energy Tracking and Reduction
–Performance Monitoring and Improvement
–Standards Development & Governance
• Application Expertise
–Industrial OT/I4.0
– Virtual Server Environments/Distributed Technology
–Coordination with Preferred local Contractors and Vendors
–Project and Construction Management – PMI Practices
–Greenfield and Brownfield Capital Investments
– Industrial Buildings, Process and Packaging Line Expansions
Full Profile at www.cfemedia.com/systemintegrator/matrixtechnologies
Pacific Blue Engineering
TRUSTED CONTROL SYSTEM INTEGRATOR PARTNER FOR MANUFACTURING, TRANSPORTATION, AND RIDE ENGINEERING
Pacific Blue Engineering is a premier automation integrator that leverages the latest industrial automation technology to deliver unique solutions for our customers’ challenges in a broad range of industries. Our true end-to-end services provide a single vision for our customers’ projects, from planning and design, to programming, building, installation, commissioning, testing, and validation.
We have served 200+ customers, in 4 countries, for 8 industries, and executed more than 1,196 jobs.
Our culture is the attitude we bring to work every morning. We work hard, do what’s right, pay attention to detail, and focus on achieving measurable results. We take pride in crossing our t’s and dotting our i’s so our customers don’t have to.
Services and Solutions
• Machine Safety Controls
• Turn-Key Control System Integration
• SCADA
• Networks & Infrastructure
• Legacy Controls Migration
• UL508A Panel Build & Design
• AutoCAD Electrical Drafting
Certifications & Associations
• TUV SUD and TUV Rheinland Functional Safety Engineers
• UL 508A Panel Shop
• CSIA member
• ISNetworld / Avetta
Full Profile at www.cfemedia.com/systemintegrator/pacificblueengineering
Founded in 1991, Patti Engineering, Inc. offers high-caliber engineering and software development services to integrate automation technology in world-class industrial facilities so that your business runs faster, smarter, and more reliably. Patti Engineering is a seven-time CSIA Certified Integrator and partners with the world’s leading industrial automation suppliers, including: Siemens, FANUC, Beckhoff, Mitsubishi, and Ignition. Modern solutions for today’s automation challenges. Digital manufacturing strategies and project management are our strong suits. Functional specs are standard and all projects have a dedicated project manager that provides regular communication throughout the process. Patti Engineering is known for becoming trusted advisors to our clients, helping them improve OEE, safety and quality in their facilities.
We have a wide range of Manufacturing Automation and Intelligence expertise:
• IIoT/Industry 4.0
• PLCs & CNCs
• Robotics
• Digital Twins
• Virtual Commissioning
• MES/SCADA
• Motion Control
• RFID/RTLS
• Vision Systems
Experienced, degreed engineers complete all of our engineering, and Licensed Professional Engineers are on staff.
Patti Engineering has experience not only in floor level automations, but also with applying Industry 4.0 technologies for Digital Transformation.
Outstanding customer satisfaction and project success earned Patti Engineering placement in Control Engineering magazine’s System Integrator Hall of Fame.
Quantum
Design Control Systems
A CONTROLS SYSTEM INTEGRATOR PROVIDING TURNKEY SOLUTIONS FROM DESIGN THROUGH COMMISSIONING
Since 1986, Quantum Design Control Systems has been a leading systems integrator serving the automation controls market by designing, building and deploying control systems throughout the world. We are committed to providing our customers with cost effective solutions using the most appropriate technology and products with proven reliability in a wide range of demanding environments and applications. Our controls engineering knowledge and panel production excellence is unique and provides customers a complete, turnkey solution.
Quantum Design’s team of engineers come from many different industry backgrounds and deliver broad ranging expertise in the following key areas:
• electrical engineering/design
• control system and panel design
• motion control a/programming
• CNC design/implementation
• Legacy system upgrades
• Logic programming and HMI development
• plant data integration, reporting and visualization
• and more….
Quantum Design provides full support throughout the project including installation support, start up, field service and training.
In addition, Quantum Design is a self-certifying, UL508A panel assembly shop and proficient at developing CE compliant controls systems. We employ the best technicians and assemblers and each system is inspected by our dedicated Quality Assurance team. Our ISO 9001:2015 Quality Management System ensures adherence to requirements and empowers us to continually improve. Quantum Design has been featured on Control Engineering’s System Integrator Giants list since 2019.
Full Profile at www.cfemedia.com/systemintegrator/quantumdesigncontrolsystems
System Integrator Corporate Close-Ups
Danny Smith
Head of Business Development
danny.smith@gotoSAGE.com www.gotoSAGE.com
Primary Industries
• Manufacturing
• Mining/Resources
• Utilities/Water/Energy
• Transport / Smart Cities
• Defence Office Locations:
• Australia - South Australia, Victoria, New South Wales, Western Australia, Queensland, Northern Territory and Tasmania
• India – Pune
ACCELERATE YOUR DIGITAL JOURNEY WITH SAGE
SAGE Group is a global company with a team of more than 720 people over two continents, committed to creating a Smarter Future, Better World.
As an integrated industrial digitalization services provider, SAGE has specialist brands and software solutions that combine to support clients to lead into the future on their digital transformation journey, with the perfect balance of technology, process, and capability. SAGE clients are world leaders and innovators looking for a smarter way of doing things and together, we are on a mission to make the lives of everybody smarter, safer, and more sustainable.
Specialist Brands
SAGE Automation Industrial automation design, delivery, and support Nukon Digital operations consultancy and delivery for smart decision making using whole-of-business insights
Embedded Expertise Matching high-calibre technical expertise with agile clients Skills Lab Creating a workforce that thinks smarter with industry 4.0 capability
Software Solutions
TilliT Manufacturing’s low-code digital platform
Addinsight Unlocking powerful transport insights using real-time movement data
Vertech
Michelle Hammer
Business Development Manager
4409 E Baseline Rd #127 Phoenix, AZ 85042 615-208-4979
vertech.com
Primary Industries
• Data Centers
• Food & Beverage
• Solar Energy
• Water & Wastewater
• Manufacturing
Other Office Locations
• Irvine, CA
• Phoenix, AZ
• Nashville, TN
• Austin, TX
• Pune, India
A "RIVER GUIDE" FOR DIGITAL INDUSTRIAL SOLUTIONS
At Vertech, we believe there's a human way to do industrial automation.
Yes, we design bulletproof MES, SCADA, OT, and Controls solutions that are a joy to use. But we're also your long-term ally. No more endless change orders. No more paying good money for a half-solution. We're here to reduce your tech-related stress, not add to it. And who knows? You might even enjoy the process.
If you need a long-term guide to help you traverse the ever-changing rapids of industrial technology, we’ve got a paddle. Jump on in.
System Integrator Corporate Close-Ups
Paul Sondreaal, Director of Business Development
Eden Prairie, MN Telephone: (952) 933-3222 paul.sondreaal@wmeng.com www.wmeng.com
Primary Industries
• Water / Wastewater
• High tech
• Oil & Gas
• Pharmacuetical or Life Sciences
• Food and Beverage
Other Office Locations
• Over 30 offices Nationally
Dino Busalachi
Dino.busalachi@bwdesigngroup.com
Craig Duckworth
Craig.duckworth@bwdesigngroup.com
636-577-8619
Primary Industries
• Manufacturing
• Chemicals, Petrochemicals
• Utilities
• Food, Beverage
• Process Industries
• Pharmaceuticals
Office Location
• St. Louis, MO
Wunderlich-Malec
WUNDERLICH-MALEC: THE GO-TO TEAM FOR
YOUR
ENGINEERING, SYSTEM INTEGRATION, AND FABRICATION NEEDS.
Clients in a wide variety of industries rely on Wunderlich-Malec for advanced engineering solutions. The demands on today’s leaders require complex solutions to help manage their business. Cost reduction, regulatory requirements, security, and rapidly changing market dynamics require fully integrated operations. Since 1981 Wunderlich-Malec has excelled at creating and deploying the total solutions they need to meet these business objectives. We believe the key to our success is our depth of talent, proven methodologies and exceptional flexibility. Our people are passionate about solving your unique engineering challenges, and with the support of industry experts behind them, they can successfully execute projects of any size while meeting the demands of your industry.
Wunderlich-Malec is a 100% employee-owned company (ESOP). With offices throughout the US and over 500 professionals on our staff, we are one of the largest and most well established engineering companies in the United States. Our success is fueled by our strong and long-lasting customer relationships guided by our 3 part culture – Our Pledge, Process and People. We’re confident that our qualified staff has the knowledge, experience and talent to create and deliver the solutions you need for your integration needs.
Full Profile at www.cfemedia.com/systemintegrator/wunderlichmalec
Velta Technology
COMPREHENSIVE MANUFACTURING AND CRITICAL INFRASTRUCTURE CYBERSECURITY SOLUTIONS
Velta Technology joined forces with Barry-Wehmiller Design Group, one of the largest System Integrators in the US, in July 2024.
By bringing Velta Technology's expertise in engineering, digital safety, and cybersecurity for the industrial space together with Design Group's extensive experience in engineering and OT consulting services, they will collectively offer unparalleled protection for industrial assets.
Together, we provide a full suite of industrial cybersecurity services, including:
• Comprehensive risk assessments and vulnerability analyses
• Development and implementation of robust cybersecurity strategies
• Integration of advanced digital safety solutions with existing industrial technologies
• Continuous monitoring and threat detection for industrial assets and infrastructure
• Incident response and remediation services
• Compliance management and regulatory guidance
• Training and awareness programs for organizations and employees
Our combined cybersecurity expertise and offerings, ensure clients receive the highest level of protection for their critical assets, enabling them to operate with confidence in an increasingly connected and complex industrial marketplace.
at www.cfemedia.com/systemintegrator/veltatechnology
System Integrator Corporate Close-Ups
Concept Systems
EFFICIENT WORKFLOWS. EFFECTIVE MANUFACTURING.
GTH
YOUR DESIGN-MINDED, SOLUTIONS-ORIENTED AUTOMATION PARTNER
Staton Apple Sales & Marketing Director
(541) 204-0405
sapple@conceptsystemsinc.com
Contact-us@conceptsystemsinc.com
Conceptsystemsinc.com
Primary Industries
• Aerospace
• Food & Beverage
• Process Industries
Concept Systems, Inc., streamlines automation to solve manufacturing challenges across industries worldwide. With decades of experience, our team delivers tailored solutions including automation consulting, controls, workcells, process control, and panel fabrication. From jet engines to French fries, we enhance manufacturing workflows with proven methodology and expert integration management. Our engineers specialize in robotic and machine vision applications, ensuring stable, consistent processes and custom panel designs through our UL508Acertified shop. Partner with Concept Systems and leverage a team of seasoned professionals dedicated to optimizing your operations and addressing persistent automation challenges.
Interstates, Inc.
TRANSFORM YOUR OPERATIONS AND MEET PRODUCTION PROMISES
Interstates, Inc. is a total systems integrator with the ability to automate all of a plant's equipment, collect and provide data reporting from operations, and design the interface with business systems to give an owner real-time tracking and control. With decades of experience and proven expertise, we partner with our clients to find industrial solutions from operational technology to analytics to automation.
Interstates, Inc.
1400 7th Avenue NE
Sioux Center, IA 51250
712-722-1662
bdev@interstates.com www.interstates.com
Primary Industries:
• Consumer Packaged Goods
• Food & Beverage
• Value-Added Agriculture
• Warehouse & Distribution
Since 1953, Interstates has thrived on solving the most complex challenges to ensure your facilities stay up and running with no unplanned downtime. As a system integrator, we have the capacity and the know-how to deliver solutions on schedule, on budget, and on target with your needs.
With a legacy of 94-years in controls and automation, George T. Hall Company (GTH) brings expertise and intuition to every solution. We are proud to hold the following certifications as a testament to our legacy as well as our commitment to quality and best practices:
• Certified to ISO 9001:2015 by DQS
• CSIA Certified System Integrator
• UL 508A and 698A
As a full-service control solutions provider, GTH specializes in the areas of:
• PLC Modernization
• SCADA/ OEE Solutions
• Combustion Technology
• Process Control Upgrades
• Control Panel Manufacturing
Controls and Automation Solutions for the Western U.S. www.georgethall.com/si/ California 714-939-7100
ADVANCING MANUFACTURING THROUGH THE MASTERY OF AUTOMATION TECHNOLOGIES
MartinCSI is a highly-qualified systems integrator that has been providing complete automation solutions to the manufacturing community for over 30 years. We offer a broad scope of automation services including control panel design, upgrades, motion controls, PLC programming, SCADA/HMI development, and robotics. We specialize in Smart Manufacturing solutions, machine vision, and machine safety. Being hardware agnostic and trained on multiple platforms allows us to work across a variety of different industries in discreet and process manufacturing. You can expect to receive detailed scopes, expert engineering, honest and regular status assessments, attention to quality, and a focus on exceeding your expectations.
Lindsey Kielmeyer, Business Development Director
Telephone: (614) 761-5600
Fax: (614) 761-5601
saleseng@martincsi.com www.martincsi.com
Primary Industries:
• Automotive
• Chemical
• Factory Automation
• Food and Beverage
• Life Sciences
System Integrator Corporate Close-Ups
McEnery Automation
OPTIMIZING ASSETS AND PRODUCTIVITY
McEnery Automation combines extensive process control knowledge with OT and IT expertise to deliver scalable, cost-effective solutions that optimize assets and productivity. We help clients with their digital transformation journey by integrating the plant floor with information systems.
McEnery Automation's engineers are experts in Process, Control, and Information systems. With over 30 years of experience, our success is rooted in hiring and developing engineers who excel in these critical areas.
Steve Holland
Info@McEneryAutomation.com
St. Louis, MO 636-717-1400
www.McEneryAutomation.com
Primary Industries:
• Food & Beverage
• Consumer Products
• Lubricants & Chemicals
• Water/Wastewater
This unique approach allows our team to not only understand the process data, but also how to put it to use by business systems and analytical tools to optimize assets and productivity.
Thermo Systems
A GLOBAL, FULL-SERVICE CONTROL SYSTEMS INTEGRATION PARTNER.
Thermo Systems is a global, fullservice control systems integration partner, providing world-class automation solutions within the District Energy, Life Sciences, and Mission Critical markets. We excel at managing and delivering turnkey projects to our EPC (Engineering, Procurement and Construction) & AE (Architect Engineer) partners while also specializing in customized direct-to-owner solutions, focusing on industries where we can offer unmatched domain knowledge to deliver the best possible services and technologies for your needs. By investing in our people, we provide a project team with the skill and expertise to overcome your biggest industrial automation and information challenges.
Sonali Shah Director, Marketing sonali.shah@thermosystems.com
In today’s manufacturing landscape, there are abundant opportunities to enhance performance; but finding the time and resources in-house can be challenging. That’s where we come in.
Our dedicated team of engineers work closely with you to understand your unique processes and identify opportunities for improvement. We then tailor value-based solutions to meet your business objectives and ensure long-term success.
Rande Allen, Vice President 855-794-7659
marketing@polytron.com www.polytron.com
Primary Industries:
• Food & Beverage
• Consumer Packaged Goods
• Life Sciences
Our in-depth understanding of the entire manufacturing landscape helps us evaluate all aspects of your plant to provide best fit solutions while managing the details to reduce project risk. We place quality and care at the center of everything we do.
Global INTEGRATOR Report SYSTEM
• Product of the Year
• Engineering Leaders Under 40
• System Integrator Giants
• System Integrator of the Year
Find award information under AWARDS at: www.controleng.com www.plantengineering.com
TRIAD CONTROL SYSTEMS
“EVERYTHING
ELECTRONS: A FULL-SERVICE AUTOMATION CONSTRUCTION COMPANY”
Who we are: Triad has revolutionized the industrial sector serving our clients for the past 50 years delivering tested and proven solutions. Whether it is E/I Design, DCS/PLC programming or MCC modular building fabrication, to E/I construction, Triad is the absolute leader when it comes to your E/I/A project.
What we offer:
• Automation Services
• Design Services
• Digital Integration Services
• Fabrication/Integration
• Analytical
• Burner Management
Who we serve:
• Petro/Chemical
• Refining
• Power Generation
• Pulp/Paper
• Midstream
• Green Energy/Renewables
Automation/Analytical/Design
• Baton Rouge, LA
• Deer Park, TX
Metal/Fabrication/Integration
• Baton Rouge, LA (833) 501-4858
TCSInfo@TheNewtonGroup.com
Contact us at QR code below:
Salas O'Brien
ENGINEERED FOR IMPACT
Salas O'Brien is an engineering and technical services firm advancing the human experience Our impact-driven team, specializing in innovative construction, automation, and turnkey solutions, helps deliver clients key goals while addressing critical business challenges like optimization, sustainability and decarbonization.
Serving both government and private sectors, we bring specialized expertise in built environment engineering, energy resiliency, process design, and consulting. We are committed to constant progress and a sustainable future, creating the best outcomes for our clients and team members.
John Glenski, Senior Director, Automation and Digital John.glenski@salasobrien.com
Unlimited license, connections, clients, and developers. SCADA, IIoT, data hub, and more all included.
Unlimited Data Access with Unified Namespace.
Infinite flexibility with built-in C#, SQL, Python 3.7 + and VB.NET.
Powerful
.NET for speed, power and reliability.
Multi-Platform support –Windows, Linux, or Docker.
Fast WebAssembly Displays, flexible Python 3.7+ integration. Includes over 70 drivers, PLC finders, OPC UA, and MQTT tools.
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Cost Effective
Highest value complete development platform. Right-sized product family with flexible pricing.
Unlimited licensing $13,300, Edge starting at $600.
FX FactoryStudio scales by I/O and number of clients.
