Projects
Three case studies, then shorter project notes with the technical detail.
What we work with. Siemens S7-1200 and S7-1500, Allen-Bradley ControlLogix and CompactLogix, Schneider Modicon, Omron, Unitronics, and the older generations of each. Ignition, WinCC, Citect and Node-RED for SCADA and screens. OPC UA, MQTT, Modbus, EtherNet/IP, Profinet and IO-Link. Where it fits, our own JasperX controller and cloud.
Case studies
R&D, Gelion Technologies
Battery test rig
A custom NodeJS application on an industrial control layer, delivered in two weeks at 40% below the hardware-only spec.
Read the case study
Manufacturing, EcoSurfaces
Automated production line
Second-hand imported machines automated into one line, with new panels to Australian standards. One operator now runs the line from a tablet.
Read the case study
Water, Generator Property Management
Off-grid pump station
An 80 kW off-grid lift station: solar for the controls, VSD pump starts that stop the generator being overloaded, and web-based monitoring.
Read the case studyMore projects, by industry
Plants, water and infrastructure
Port of Newcastle
Dredge HVAC controls
We replaced the dredge’s obsolete air conditioning controls with one JasperMate controller for three zones, plus generator monitoring on the bridge. Installation took three days and the vessel sailed the next day.
Omega Chemicals
Sulphuric acid storage controls
Two 98% sulphuric acid tanks were the first load on a new plant MCC, built around a Siemens S7-1200 with remote I/O at the tanks and sized for the rest of the plant to move across in stages.
City of Newcastle
Summerhill SCADA
We built central leachate control on Ignition SCADA and Siemens PLCs, linking remote ponds, pumps and valves over MQTT. Council operators get secure remote access, interlocks and the records the EPA asks for.
Biodiesel Australia
EPA compliance upgrade
The tanks had no level switches or condition alarms. To meet updated EPA requirements, we delivered the design, PLC and HMI programming, installation and commissioning, all within a planned plant shutdown.
Munzing Australia
Tank control system upgrade
We upgraded the I-Release and Sylvic production tanks to PLC control of multi-stage temperature and variable-speed mixing. A dedicated wireless network lets operators run it from a tablet anywhere on the floor.
Formit Services
Machine downtime tracking
Downtime was tracked by hand. Gateways on two rotational moulding machines now publish PLC data over MQTT to the cloud, giving live production counts, downtime Pareto charts and the data for OEE.
Concrete panel manufacturer
Concrete batching automation
We automated concrete batching and discharge, from the system design and PLC batching program to PC software for recipes and monitoring, with production data collected and monitored in the cloud.
Machines, lines and new builds
Pacific National
Drop table control upgrade
We replaced an outdated PLC on a rail drop table and indexer with a Siemens S7-1200, covering 96 I/O points, 20 MCC outlets, the VSD interface and remote monitoring. Operators were trained at handover.
EcoSurfaces
Calibrator line control panel
This 415 V panel runs a stone calibrator line’s high-power spindle motors, VSDs, water pumps and pneumatics. Hardwired safety relays, E-stop isolation and light curtains protect the operators on the line.
Confidential
185 kW fluid coupling drive
We designed the controls and electrical system for a 185 kW belt conveyor with a fluid coupling and regenerative winch drive, across five voltage levels. A CompactLogix 5380 runs staged fill logic for smooth starts.
Noble Craft Distillery
Distillery control system
We delivered the electrical and automation for a new Brookvale distillery. A Siemens PLC and SCADA control temperature and flow in the tuns and fermenters, with layered interlocks for a flammable process.
Noble Craft Distillery
Hazardous area MCC
We designed, built and commissioned an 18-outlet MCC for a classified hazardous area, with DOL starters, VSDs, intrinsically safe barrier circuits and solid-state low-water cutouts protecting the boiler.
Other work
Gelion Technologies
Battery storage monitoring
Gelion’s battery storage systems needed remote monitoring. We merged inverter, BMS and PLC data into one stream, sent over MQTT to InfluxDB on AWS, where the team runs maintenance and performance checks.
Lovells Springs
Robotic spring handling
A camera finds springs on a pallet, our software calculates their coordinates, and a Yaskawa Motoman arm places them on the conveyor. The same software runs the whole sequence, from image capture to robot commands.
Or send an enquiry with photos of the panel and the screen. Most small jobs are quoted within two business days.