Twelve disciplines. One control system.
Every service below is delivered by the same team that scoped your project — not handed to a subcontractor once the proposal is signed. Below, each discipline as we actually define it, including where it starts and where it hands off to the next.
SCADA Systems
Supervisory control and data acquisition sits at the centre of most of our projects, because it's where operations decisions actually get made. We build SCADA systems that reflect a genuine alarm philosophy — priority-rationalised, not defaulted to "high" across the board — and architecture that survives a single point of failure without taking the operator's visibility with it.
Our SCADA work covers architecture design, redundancy planning (hot-standby servers, network path diversity), historian configuration, and the reporting layer operations managers actually read. We build primarily on Ignition for its licensing model and web-native deployment, and on Siemens WinCC or Rockwell FactoryTalk View where the client's existing asset base makes that the better fit.
PLC Programming
Programmable logic controller code is the layer where design intent either survives contact with the real plant or doesn't. We write structured, tag-named, commented logic across ladder, structured text, and function block — whichever the platform and the maintenance team's own competency calls for, not whichever is fastest for us to write.
Every program is version-controlled, factory tested against a written functional description before it reaches site, and delivered with a change log your own engineers can actually follow six months later. We work across Rockwell ControlLogix and CompactLogix, Siemens S7-1200/1500, Beckhoff TwinCAT, and CODESYS-based OEM controllers.
HMI Development
A human-machine interface is only as good as the decisions it helps an operator make at 2am during an alarm cascade. We design HMI screens against ISA-101 principles — greyscale process graphics, colour reserved for deviation from normal, navigation depth kept to three clicks or fewer between any two related screens.
Work includes screen hierarchy design, alarm banner and annunciation configuration, trend and historian screen design, and operator sign-off testing before go-live. We build on Ignition Perspective and Vision, Siemens WinCC, Rockwell FactoryTalk View, and Beckhoff TwinCAT HMI, matched to the runtime already on site.
RTU Integration
Remote terminal units are how a control system stays connected to assets that don't have the power reliability, network backhaul, or physical access of a central plant. We specify and configure RTU hardware for solar-powered pump stations, unmanned substations, and roadside monitoring points where the next site visit might be weeks away.
This includes protocol selection (DNP3, Modbus TCP/RTU, IEC 60870-5-101/104), power budget calculation for battery/solar sites, local logic for fail-safe behaviour during comms loss, and integration back into the central SCADA historian without flooding it with duplicate or stale data during a reconnect.
Telemetry Systems
Telemetry is the wide-area network problem underneath every distributed asset base — cellular, radio, or fibre backhaul carrying data from sites that might be a hundred kilometres apart. We design telemetry networks around actual coverage data, not carrier marketing maps, and build in store-and-forward buffering so a comms outage doesn't become a data-loss event.
Scope typically includes radio path surveys, cellular APN and failover configuration, telemetry gateway selection, and central historian architecture sized for the actual tag count and polling rate — not an assumed figure from a spreadsheet template.
OT Cybersecurity
Operational technology networks fail differently to IT networks — a patch applied without testing can stop a pump, not just a laptop. We work to the IEC 62443 zone-and-conduit model: segmenting control networks from corporate IT, defining trust boundaries between safety, control, and supervisory layers, and building monitoring that flags anomalies without generating so many false positives that operators start ignoring it.
Work includes network architecture review, firewall and DMZ configuration between OT and IT, remote access hardening (no more flat VPNs into the control LAN), asset inventory and vulnerability assessment, and incident response planning specific to the control system in question.
MES Solutions
A manufacturing execution system only earns its keep if the data it reports matches what actually happened on the line — not what the ERP assumed happened. We build MES layers that pull directly from PLC and SCADA data: production counts, downtime reason capture, batch genealogy, and OEE calculated from real machine states rather than manually logged estimates.
Typical scope covers downtime and reason-code capture at the machine level, batch and lot traceability for food, beverage, and regulated manufacturing, and OEE dashboards operators trust because the underlying data collection was designed with them, not around them.
Cloud Integration
Cloud integration is where we're most conservative, because the control network's isolation is not something to trade away for a dashboard. We build one-directional, edge-to-cloud data pipelines — historian replication, MQTT Sparkplug B publishing, or scheduled batch export — so a corporate BI tool or a head-office dashboard can read plant data without ever gaining a write path back into the control system.
Common outcomes include multi-site executive dashboards, long-term historian archiving to reduce on-prem storage load, and integration with enterprise asset management or ERP systems for maintenance and inventory workflows.
Electrical Design
Control system reliability starts with the electrical design underneath it — switchboard layout, load calculations, and protection coordination that give the PLC hardware a stable, correctly rated environment to run in. We design low-voltage switchboards and control panels to AS/NZS 61439 and site wiring to AS/NZS 3000, with drawings issued in a format your electrical contractor can build from without a site visit to clarify intent.
Scope covers single-line diagrams, panel layout and thermal calculations, cable schedules, protection and coordination studies, and hazardous area classification where the site requires it.
Commissioning & Testing
Commissioning is where design assumptions meet a live plant, and it's the stage most likely to be rushed by integrators who quoted the build but under-scoped the cutover. We run factory acceptance testing off-site against a written test plan before anything ships, followed by staged site acceptance testing, loop-by-loop verification, and a cutover sequence built around your maintenance windows, not ours.
Every commissioning plan includes a documented rollback procedure, a punch list tracked to closure rather than left in an email thread, and formal operator sign-off before we consider the project complete.
Control System Documentation
Documentation is usually the first thing cut under schedule pressure and the first thing your team needs the day something fails at 3am. We treat as-built drawings, I/O schedules, network diagrams, and functional description documents as deliverables with the same priority as the working system itself — updated at each project stage, not reconstructed retrospectively at handover.
Standard deliverables include control philosophy documents, cause-and-effect matrices, I/O schedules cross-referenced to physical terminal numbers, network architecture diagrams, and a change log covering every modification made after go-live.
End-to-End Project Delivery
Most of the services above are delivered together, on a single program, under one project engineer who's accountable from the first site audit to the final as-built drawing. That's a deliberate structural choice: it removes the handover gaps between electrical design, controls engineering, and commissioning that cause the majority of post-handover defects we get called in to fix on other integrators' work.
End-to-end delivery includes program scheduling around your operational constraints, subcontractor coordination where civil or mechanical trades are involved, budget tracking against the original scope, and a single point of contact throughout — not a different name at each project stage.
Tell us which of these your current system is missing.
Most engagements start with a gap between one or two of the disciplines above — we'll help you find it.