Controls and Automation
Modern material movement equipment requires sophisticated control systems to achieve peak performance, safety, and efficiency. At Almac Industrial Systems, we bring over two decades of hands-on experience designing, fabricating, programming, installing, and commissioning custom automation solutions for material handling equipment across diverse industrial applications.
Our control systems engineering team has successfully deployed automation solutions in automotive manufacturing, food processing, sterilization process, pharmaceutical production, and warehouse distribution centers—giving us deep expertise in the unique challenges each industry presents.
Custom Automation Solutions for Material Handling Equipment
Every material handling system we’ve engineered tells a story of precision and reliability. From the innovative robotic cell that was integrated into an assembly line for a major automotive supplier, to the sophisticated steel sorting system in a forming mill, to the intricate conveyor networks we’ve integrated in pharmaceutical clean rooms, our solutions are built to perform under real-world conditions.
Our comprehensive automation services include:
- PLC Programming and Integration – We work with industry-leading platforms, including Rockwell and Siemans, models as dictated by required integration with end-user existing systems.
- SCADA and MES Integration – Seamless connectivity with your existing enterprise systems for real-time data visibility
- Safety System Implementation – Cat 3/SIL 2-rated safety circuits and emergency stop systems, as well as integrated safety circuits tailored to meet application-specific needs, ranging from high-level redundant systems to simple e-stop circuits.
- Variable Frequency Drive (VFD) Configuration – Precise motor control for conveyors, lifts, and material transport systems
- Human-Machine Interface (HMI) Development – Intuitive operator controls designed for your specific workflows
Proven Results in Material Movement Equipment
Our clients consistently report significant improvements in throughput efficiency and reductions in unplanned downtime after implementing our control systems. These results stem from our methodical approach to understanding your material flow patterns and designing automation that enhances rather than complicates your operations.
Advanced Control System Features
Real-Time Process Control
Our PLC-based systems monitor and control every aspect of your material handling equipment performance, from conveyor speeds and load balancing to automated sorting and quality checkpoints. Each system includes comprehensive fault detection and automatic recovery protocols.
Integrated Safety Systems
Safety remains paramount in every control system we design. Our safety-rated PLCs incorporate dual-channel safety inputs, monitored light curtains, and emergency stop circuits that meet or exceed OSHA and ANSI safety standards for material handling equipment.
Remote Diagnostics and Monitoring
Built-in remote access capabilities allow our technicians to diagnose issues, update programming, and optimize performance without costly site visits. Our systems generate detailed maintenance alerts and performance analytics to prevent equipment failures before they occur.
Industry-Specific Control Solutions
Automotive Manufacturing
High-speed conveyor systems with precise positioning controls for assembly line material movement, including automated guided vehicle (AGV) integration and robotic cell coordination.
Food and Beverage Processing
Sanitary design controls with wash-down rated enclosures, temperature monitoring, and HACCP-compliant tracking systems for ingredient handling and packaging lines.
Pharmaceutical and Sterilization
Clean room compatible automation with compliant data logging, batch tracking, and validation documentation support for material handling equipment in regulated environments.
Complete System Integration
Our controls and automation solutions seamlessly integrate with:
- Warehouse Management Systems (WMS) – Direct communication for inventory tracking and automation of order fulfillment
- Enterprise Resource Planning (ERP) – Provision of production data and information for end-user ERPs
- Robotic Systems – Coordinated control of material handling robots and automated storage/retrieval systems
- Quality Control Equipment – Automated reject handling and quality data collection integration
Related Services
Discover how our specialized engineering services complement your controls and automation project:
- Control Panels – Custom electrical enclosures designed and built to your specifications
- Wiring and Piping – Professional installation and commissioning of all control system infrastructure
Why Choose Almac for Your Material Handling Automation
With over 50 years of specializing exclusively in material handling equipment automation, we understand the critical importance of system reliability in your operations. Our team of certified control systems engineers have programmed hundreds of PLC systems and commissioned automation solutions in 15+ countries.
Every project includes comprehensive documentation, operator training, and ongoing technical support to ensure your material movement equipment delivers consistent performance year after year.
Ready to optimize your material handling operations? Contact our controls engineering team at 905-713-1377 or info@almac.com to discuss your automation requirements.