Embedded Files
Selected projects from our work across manufacturing, infrastructure, and R&D. Each project was delivered by our in-house engineering team, from design through to commissioning.
CASE STUDIES
CASE STUDIES
INDUSTRIAL CONTROLS WITH CUSTOM SOFTWARE
INDUSTRIAL CONTROLS WITH CUSTOM SOFTWARE
Battery Test Rig and Battery Management System
Gelion Technologies
Battery Test Rig and Battery Management System
Gelion Technologies
Category label: R&D & Custom Systems
When a traditional automation spec called for expensive, inflexible hardware, we provided a new path. We saved our client 40% and delivered a usable system in 2 weeks by building a custom NodeJS application on top of a robust industrial control layer, giving their R&D team the agile, future-proof platform they needed.
MANUFACTURING
MANUFACTURING
Automated Production Line
EcoSurfaces
Automated Production Line
EcoSurfaces
Category label: Manufacturing
In collaboration with EcoSurfaces, we delivered automation across the entire production line. The results: 30% reduction in potential workplace injuries, up to 27% reduction in defects, and up to 25% savings in labour costs. Modern control panels with tablet-based monitoring replaced manual operation across the facility.
WATER AND WASTEWATER
WATER AND WASTEWATER
Pump Station Electrical System Upgrade
Generator Property Management
Pump Station Electrical System Upgrade
Generator Property Management
Category label: Water & Infrastructure
GPM needed to manage an 80 kW dirty water lift station in a remote, off-grid location. High pump startup currents were damaging the generator, and frequent manual inspections were costly. We delivered an autonomous control system with solar power, VSD-controlled pump starts, and web-based remote monitoring - cutting site visits, fuel consumption, and maintenance costs.
PROJECTS BY INDUSTRY
PROJECTS BY INDUSTRY
Manufacturing
Manufacturing
Noble Craft Distillery - Control System Design
Noble Craft Distillery - Control System Design
BFull electrical and automation package for a new craft distillery in Brookvale. We designed the complete control system around a Siemens PLC and SCADA platform, with multi-layered safety interlocks for managing a hazardous, flammable environment. Automated temperature and flow control for the Hot Liquor Tun, Mash Tun, and fermenters ensures repeatable batch quality. IO-Link architecture reduced wiring complexity and created an expandable platform for future growth.
Munzing Australia - Control System Upgrade
Munzing Australia - Control System Upgrade
Complete control system upgrade for Munzing's 'I-Release' and 'Sylvic' production tanks. Delivered PLC-based multi-stage temperature control and variable-speed mixing, with a dedicated wireless network allowing full process control from a ruggedised mobile tablet anywhere on the plant floor.
Concrete Batching System - U-Panel Manufacturing Automation
Concrete Batching System - U-Panel Manufacturing Automation
Automation of concrete batching and discharge for a panel manufacturing facility. Designed the full system architecture, developed PC software for recipe management and monitoring, programmed the PLC for batching execution, and built cloud infrastructure for remote process monitoring and data collection.
Formit Services - Production Monitoring & Downtime Tracking
Formit Services - Production Monitoring & Downtime Tracking
Engineered a complete IIoT infrastructure for a rotational moulding facility, connecting two critical machines to a cloud-based monitoring platform. Machine-level gateways publish PLC data via MQTT to an IIoT platform, delivering live production counters, automated Downtime Pareto charts, and the data foundation for OEE calculation. Moved the client from manual tracking to data-driven operations.
R&D & Custom Systems
R&D & Custom Systems
Gelion Technologies - BESS Monitoring System
Gelion Technologies - BESS Monitoring System
Gelion needed complete remote oversight of their Battery Energy Storage Systems. We engineered a unified data pipeline that integrated third-party inverters, battery management systems, and a Siemens PLC into a single data stream. A custom software layer on a dedicated Mini-PC transmits real-time data via MQTT to a cloud-hosted InfluxDB on AWS, giving Gelion's team the insights needed for proactive maintenance and performance validation.
Lovells Springs - Advanced Robotics for Spring Handling
Lovells Springs - Advanced Robotics for Spring Handling
Designed and implemented a robotic pick-and-place system for a spring manufacturing line. The system uses a video recognition camera to identify and locate springs on a pallet, calculates coordinates, and directs a Yaskawa Motoman robotic arm to pick and place them onto a conveyor. Custom software manages the full workflow: image capture, recognition, coordinate calculation, and robot commands.
Water, Environment & Infrastructure
Water, Environment & Infrastructure
City of Newcastle - Summerhill Waste Management Centre SCADA
City of Newcastle - Summerhill Waste Management Centre SCADA
Delivered a centralised, fail-safe control and monitoring system using Ignition SCADA and Siemens PLCs to ensure strict EPA compliance for leachate management. Implemented a highly secure, Zero-Trust MQTT architecture to integrate remote ponds, pumps, and valves across multiple sites. The system provides council operators with secure remote access, automated interlocking, and detailed historical data logging for regulatory audits.
Biodiesel Australia - Electrical System Upgrade (EPA Compliance)
Biodiesel Australia - Electrical System Upgrade (EPA Compliance)
Biodiesel Australia required an electrical system upgrade to meet updated EPA regulations. Storage and reaction tanks were lacking level switches and condition alarms. We delivered the full package: electrical and control engineering design, schematics, PLC programming with HMI, supply, installation, and commissioning - all completed within a planned plant shutdown. Commissioning reports and full documentation are provided on handover.
Have a project in mind?
Call us on 0401 434 787 or email alex@controlx.au
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