Engineering and development
We create your projects from scratch, you won't have to worry about anything.
Clearly methods and prices, budget on the basis of your specifications. If necessary, we help you in drafting the preventive specifications with a preliminary analysis.
The process
Analysis of the requirements
Analysis of the requirements
Analysis of the requirements and in -depth study of design needs
Requirements collection
Interviews, questionnaires, analysis of current processes.
Context analysis
Study of existing flows and organizational constraints.
Gap analysis
Identification of deviations compared to the objectives.
Process & Operator XP
Mapping of the process and the operator experience.
Design
Design
Automation architecture
Choice of components, I/O, sensors and actuators.
API design
Interface and services design
Functional specifications
Drafting of requirements and functional specifications for plant and software, with continuous and integrated multidisciplinary collaboration.
Scalability and performance
Growth -oriented design and high loads.
POC
POC
Interactive prototype
Development of a prototype with high-level functionalities to validate the logic.
Technical demo
Implementation of key functionality to be validated.
Feasibility test
Verification on real data and integration with existing environments.
Validation with stakeholder
Feedback collection on functionality, IU and flows.
Production
Production
Putting in production
Installation and deployment on plant devices.
Monitoring
I/O checks, verification of application logic and functional safety, and on-site handover.
Hardening
Optimization and safety of system and application.
Support
On-site and remote support, troubleshooting, and interventions to ensure operational continuity.
Use Case Tobacco Packaging
PLC software development for packaging machines in the tobacco sector
Support the creation of new packaging machines by increasing development capacity, software quality and line performance.
For a manufacturer of packaging machines in the tobacco sector we collaborated on the development of a new generation of machines, operating within the customer's proprietary automation framework. The activity included the development of PLC logic, safety functions and motion control, guaranteeing software quality, compliance with standards and machine performance.
The activity was carried out in close collaboration with the customer's technical teams, following a structured approach to PLC software design. Commissioning took place directly on the testing line, with software debugging, optimization and validation activities before final delivery.
Technical architecture
- PLC logic development according to the customer's automation framework
- Implementation of integrated safety functions compliant with regulations
- Motion control development for machine axes and kinematics
- Modular and reusable software architecture
- Management of machine states, automatic cycles and diagnostics
- Online testing commissioning and commissioning support
Results
- Increased customer development capacity thanks to 6 dedicated PLC engineers on 4 parallel orders
- Reduction of cycle time by 10% compared to the previous generation of machines
- Greater stability and quality of the software during testing and start-up
- Reduction of bugs in the final phase and more reliable delivery to the end customer
- Effective and integrated collaboration with the customer's technical teams
Use Case : PROCESS CONTROL SYSTEMS
Control software for ozone and water treatment systems
Automate the control of ozone generators to improve water quality, safety and energy efficiency.
For a manufacturer of water treatment plants we developed the control software for ozone generators, pumps, valves and advanced sensors. The activity included complete engineering (requirements, control narrative, I/O list and software architecture), PID tuning and implementation of multi-variable controls.
The system includes an industrial HMI for monitoring and diagnostics, a complete FAT with simulations and control tuning, and integration with supervision and data logging systems. This enables traceability of critical parameters, historical analysis and compliance reporting.
Technical architecture
- Siemens TIA Portal PLC development for process logics
- PID and multi-variable controls for ozone generators
- Industrial HMI for monitoring, alarms and diagnostics
- Centralized data logging with history of critical parameters
- Integration with SCADA systems and reporting
- Simulations and virtual FAT to reduce commissioning times
Results
- More stable and automated process with reduction of control drifts
- Improvement of water quality and system safety
- Reduction of energy consumption and optimization of cycles
- Greater transparency and traceability for audits and compliance
- Significantly reduced commissioning and plant start-up times
Use Case : SUPERVISION IN THE AIRPORT ENVIRONMENT
Logistical SCADA system for managing airport baggage flows
Optimize the supervision of baggage flows, reduce routing errors and improve response times.
We have created a logistics SCADA system based on WinCC OA for monitoring baggage flows in the airport environment. The supervision pages (overview, detail and tracking) allow you to control lines, belts, buffers and automatic warehouses in real time, with advanced management of alarms, trends and system status.
Integration with PLCs and airport management systems occurs via industrial drivers and an ActiveMQ message broker, ensuring reliable synchronization of events and process data. Graphic standardization and industrial UX facilitate the work of operators and maintainers and form the basis for KPIs and predictive maintenance.
Technical architecture
- SCADA WinCC Open Architecture with overview, detail and tracking pages
- PLC integration via OPC UA and proprietary drivers
- ActiveMQ message broker for events, alarms and data stores
- Backend services in C
- Centralized data store for historical trends and reports
- Operational dashboards and monitoring tools for maintainers
Results
- Clearer and more efficient supervision of lines, belts and automatic warehouses
- Reduction of routing errors and better control of flow incidents
- Greater operational responsiveness thanks to optimized dashboards and contextualized alarms
- Ready basis for advanced KPIs and predictive maintenance models
Contact us
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