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PiControl Solutions provides design and integration of many small, medium and large-scale PLC (Programmable Logic Controller), DCS (Distributed Control System), HMI (Human Machine Interface) and SCADA (Supervisory Control and Data Acquisition) systems for automatic control of new laboratory and industrial systems or modernization and maintenance of the existing ones using major platforms Siemens, Rockwell Automation, Wonderware, GE, Inductive Automation, Ignition and others. 

By knowing many PLC and DSC systems and the way of how to program them PiControl can also provide powerful services in:

• In primary or advanced process control (APC), rule-base or sequence, process safety or any other custom-made control logic.
• Preparation of preliminary and detailed automation design study for any laboratory and/or industrial unit.
• PLC equipment installation, testing, user training and continuous maintenance of the automation system within and beyond the warranty period is provided.

PiControl’s engineers are the experts in:

PLC PROGRAMMING

• PLC System Architecture Design and Hardware Engineering
• Functional Design (FDS) and Detail Design Documentation (DDS)
• PLC Programming in accordance with IEC 61131-3
• Safety PLC Programming
• Programming Standards Development
• Advanced Algorithms and PIDs
• Migration of Legacy Systems
• Interface to third party systems like vision, RFID and Barcode systems, Drives, various Field Instruments and Robots.
• PLC Based Recipes and Batch System Programming according to ISA S88 Standards
• Simulation and Complete Offline Testing

DCS PROGRAMMING

• DCS System Architecture Design and Hardware Engineering
• Functional Design (FDS) and Detail Design Documentation (DDS)
• DCS Logic Development using advanced techniques like CFC, SFC and SCL
• DCS Graphics Development and Configuration of Operator Stations
• Cause & Effect Matrix Designing for Safety Systems
• Third Party Software / Hardware connectivity
• Migration of Legacy DCS
• Simulation and Testing
• Operator Training Systems

HMI AND SCADA DESIGN

• Functional Design (FDS) and Detail Design Documentation (DDS)
• Graphics Development for Operator Panels, Touch Panels, and SCADA Systems
• Standard Objects and Templates Development
• GAMP Compliant configuration and Audit Trails in accordance with 21 CFR Part 11
• Creating Functions and Actions for Dynamic Process Objects using various Scripting languages like ANSI-C, VB, Python.
• SCADA System Migration and Upgradation
• Customized Report Generation with Crystal Reports, Microsoft SQL Server
• Reporting Services (MSSRS), MS-Excel, MS-Access

BATCH SYSTEMS DESIGN AND PROGRAMMING

• Batch Software Engineering and Configuration in accordance with ISA S88 Standards
• Recipe Management
• Batch Scheduler and Campaign Management
• Batch Report Generation
• Simulation and Testing

PiControl’s expertise also includes Manufacturing Execution System (MES) services: computer-based system used in manufacturing industries to monitor, control, and manage production processes on the shop floor.  We can provide real-time visibility, data collection, and analysis of manufacturing operations, helping to optimize production, improve quality, and enhance overall efficiency.  We bridge the gap between enterprise-level planning systems (such as ERP systems) and the control systems on the shop floor. 

The benefits of MES contribute to improved productivity, reduced costs, and increased customer satisfaction.  By providing real-time visibility, enabling quality control, and streamlining operations, MES empowers users to make informed decisions, optimize resources, and drive continuous improvement in manufacturing processes.

MANUFACTURING EXECUTION SYSTEM (MES) SERVICES

• Performance Data and OEE
• Plant / Machine Level Dashboards
• Downtime Reasons and Detailed Analysis
• Scheduling
• SPC
• Track and Trace
• Recipe and Product Management
• Integration with Barcode, Scanners, Cameras
• Data Historians

PiControl Solutions provides mostly automated solutions using:

• Totally Integrated Automation Portal (TIA Portal) system, which is SIEMENS Automation Design platform designed and used mostly in small to medium size manufacturing industry or in research facilities and laboratories.
• SIMATIC PCS 7 system, which is SIEMENS Distributed Control System designed and used mostly in large manufacturing industry.
• Rockwell Logix Platform, which is Rockwell Automation powerful PLC system mostly used in small to medium size manufacturing industry or in research facilities and laboratories.

Knowledge and experience of PiControl Solutions engineers is gained in numerous laboratory and industrial automation projects present in pharmaceutical and polymer industries, research facilities, refineries, and power plants.