PLC Programming & Control Systems
Master your manufacturing processes with robust ladder logic, seamless SCADA integration, and reliable controller architectures tailored to your plant floor.
Siemens PLC Programming
Expert engineering for SIMATIC S7-1200, S7-1500, and S7-300/400 platforms using TIA Portal for complex process automation.
Allen-Bradley Integration
Comprehensive Rockwell Automation solutions, programming ControlLogix, CompactLogix, and Micro800 controllers in Studio 5000.
Multi-Vendor PLCs
Broad expertise across Schneider Electric (Modicon), Mitsubishi (MELSEC), Delta, and Omron controllers for diverse plant standards.
HMI Design & Programming
Intuitive, high-performance Human Machine Interfaces (PanelView, SIMATIC Basic/Comfort) that give operators clear, actionable control.
SCADA System Integration
Plant-wide supervisory control and data acquisition using modern platforms like Ignition, WinCC, or FactoryTalk View SE.
Legacy PLC Migration
Risk-mitigated upgrades from obsolete platforms (e.g., SLC 500, PLC-5, S7-300) to modern control architectures with minimal downtime.
Ladder Logic & Structured Text
Development of clean, strictly documented, and highly efficient IEC 61131-3 compliant control programs.
Control System Audits
Comprehensive diagnostics of existing logic and hardware to identify bottlenecks, safety risks, and optimization opportunities.
Process Automation
Continuous and batch process control programming tailored for water treatment, chemical, or heavy manufacturing.
Motion Control
Precise servo and stepper motor integration within the PLC architecture for highly synchronized packaging and assembly machines.
Industrial Networks
Architecture and configuration of robust communication backbones via PROFINET, EtherNet/IP, Modbus TCP/RTU, and Profibus.
As-Built Documentation
Delivery of comprehensive control narratives, I/O lists, and updated electrical schematics upon project completion.
Motor & VFD (Inverter) Services
Optimize torque, achieve precision speed control, and drastically cut energy waste with expert variable frequency drive and motor integration.
VFD Installation & Setup
Complete installation, wiring, and initial configuration of Variable Frequency Drives from major brands like ABB, Danfoss, and Yaskawa.
Motor Sizing & Selection
Precise calculation of torque requirements, duty cycles, and load characteristics to select the optimal AC/DC motor for your application.
VFD-PLC Integration
Seamlessly network your drives to the central PLC using fieldbus protocols like EtherNet/IP, PROFINET, or Modbus RTU/TCP.
Advanced Vector Control
Parameter tuning for sensorless vector and closed-loop control to achieve precise speed regulation and high starting torque.
Soft Starter Installation
Reduce mechanical stress and inrush currents on large motors with professionally sized and programmed soft starters.
Motor Troubleshooting
Rapid diagnostics of winding insulation failures, bearing faults, overcurrent trips, and phase imbalances to minimize downtime.
Energy-Efficient Retrofits
Upgrade legacy fixed-speed systems to VFD-driven IE3/IE4 motors for massive energy savings on pumps and fans.
MCC Integration & Sizing
Design and integration of Motor Control Centers, centralizing starter and drive logic for entire production lines.
VFD Parameter Tuning
Expert optimization of acceleration/deceleration ramps, PID loops, and overload limits for unique load profiles.
Harmonic Mitigation
Installation of line reactors, chokes, and active harmonic filters to protect grid power quality from VFD-induced noise.
Motor Starter Sizing
Design and specification of Direct-On-Line (DOL) and Star-Delta starter circuits with proper thermal overload protection.
Dynamic Braking Solutions
Implementation of braking resistors and regenerative braking systems for high-inertia loads requiring rapid deceleration.
Industrial Control Panel Boards
Custom-designed, compliant Motor Control Centers and PCC panels built to withstand extreme industrial environments and engineered for flawless execution.
New Panel Design & Assembly
End-to-end design, fabrication, and installation of bespoke control panels built to stringent industrial standards and tailored to your process.
Troubleshooting & Fault Diagnosis
Rapid isolation of electrical faults, burnt contactors, blown fuses, and intermittent logic issues directly on the plant floor.
Motor Control Center (MCC)
Centralized, modular panel assemblies designed for safe, highly organized distribution of power to multiple industrial motors.
Power Control Center (PCC)
Main incoming low-voltage power distribution panels engineered to handle massive plant loads with proper breaker coordination.
Rewiring & Component Prep
Professional clean-up of messy, "spaghetti" wiring, replacing degraded components and restoring proper wire duct organization.
Panel Modernization
Upgrading obsolete electromechanical relay logic to compact PLC-based architectures, freeing up panel space and increasing reliability.
Schematic & Wiring Diagrams
Creation of detailed, standard-compliant electrical drawings, terminal block layouts, and BOMs using modern CAD software.
Explosion-Proof (Ex-d) Panels
Design and integration of heavy-duty, flameproof enclosures for hazardous zones (oil & gas, chemical processing).
Instrument & Control Panels
Specialized local control panels housing PLCs, I/O modules, transducers, and signal isolators for localized process areas.
Panel Thermal Management
Calculation and installation of panel cooling fans, louvers, and industrial AC units to prevent heat-induced component failure.
VFD & Soft Starter Panels
Custom enclosures housing massive drives, completely integrated with line reactors, bypass contactors, and circuit breakers.
Factory Acceptance Testing
Rigorous FAT procedures including power-on testing, I/O simulation, and interlock verification before the panel ever ships.
Power Factor Improvement (PFI) Panels
Eliminate utility penalties and optimize plant power consumption with intelligently sized capacitor banks, APFC relays, and comprehensive power quality audits.
New PFI Panel Installation
Turnkey design and installation of robust Power Factor Improvement panels tailored to your facility's total inductive load.
APFC Relay Setup
Configuration of Automatic Power Factor Correction (APFC) relays to dynamically switch capacitor steps based on real-time load.
Capacitor Bank Sizing
Engineering precise kVAr requirements to ensure sufficient reactive power compensation without risking over-correction.
PFI Troubleshooting
Rapid diagnostics of failing PFI panels, addressing blown fuses, burnt contactors, and degraded cylindrical or box-type capacitors.
Power Quality Audits
Comprehensive site analysis using power quality analyzers to log voltage dips, current imbalances, and true power factor over time.
Detuned Reactors
Installation of detuned reactors (chokes) in series with capacitors to prevent resonance in environments with high VFD/non-linear loads.
Active Harmonic Filters
Deployment of Active Harmonic Filters (AHF) for facilities requiring strict IEEE 519 compliance and mitigation of high-order harmonics.
Penalty Eradication
Directly targeting and eliminating utility reactive power penalties, often achieving ROI on the PFI panel within 12-18 months.
Capacitor Duty Contactors
Upgrading standard contactors to specialized capacitor-duty variants equipped with pre-charge resistors to handle high inrush currents.
Routine Maintenance
Scheduled capacitance testing, thermal imaging of busbars, and ventilation checks to prevent catastrophic capacitor bursts.
Real-Time Monitoring
Integration of digital energy meters with Modbus TCP/IP for continuous, remote visibility into plant power quality and PF status.
Surge Suppression (TVSS)
Implementation of Transient Voltage Surge Suppressors within the PFI panel to protect sensitive capacitor banks from grid spikes.
Boiler Panel & Control Systems
Enhance thermodynamic efficiency and plant safety with advanced combustion control, BMS integration, and strict flame safeguard architectures.
New Boiler Control Panels
Design and commissioning of complete control panels for industrial steam and hot water boilers, ensuring flawless operational logic.
Boiler Panel Troubleshooting
Rapid fault finding for nuisance burner lockouts, ignition failures, sensor faults, and degraded relay logic to restore steam production.
Combustion Control Systems
Implementation of cross-limiting air/fuel ratio control loops to maximize fuel efficiency and minimize harmful emissions.
Flame Safeguard (BMS)
Integration of highly reliable Burner Management Systems to ensure safe light-off, continuous flame monitoring, and secure shutdown.
PLC & SCADA Integration
Networking the boiler control panel to the main plant SCADA for centralized monitoring, historical trending, and remote alarming.
Panel Retrofits & Upgrades
Upgrading mechanical cam-actuated burner controls and aging relays to modern, digital parallel-positioning logic systems.
Feedwater & Level Control
VFD integration for feedwater pumps and multi-element drum level control to prevent thermal shock and boiler starvation.
Pressure & Temp Monitoring
Installation and calibration of high-accuracy steam pressure transmitters and RTDs/Thermocouples for precise closed-loop control.
Draft Control Integration
VFD integration for Induced Draft (ID) and Forced Draft (FD) fans to maintain optimal furnace pressure and airflow.
Blowdown Control Systems
Automation of continuous and surface blowdown valves based on conductivity sensor feedback to manage water chemistry.
Multi-Boiler Sequencing
Intelligent lead/lag control logic to cycle multiple boilers based on plant demand, extending equipment lifespan.
Safety Interlock Testing
Rigorous functional verification of all limit switches, pressure cut-offs, and purge timers to meet stringent safety codes.
Engineering Engagement Models
From built-to-print panel fabrication to full turnkey machine commissioning.
Panel Fabrication
Build-to-print or custom engineering. We construct robust, [X] compliant control panels in our dedicated fabrication facility.
- [X] Certified
- Rigorous QA Testing
Targeted Retrofits
Modernize obsolete PLCs and drives while preserving your existing mechanical investments to eliminate downtime risks.
- Legacy PLC Migration
- Zero-Downtime Cutovers
Turnkey Integration
Single point of accountability. We handle electrical design, panel build, programming, and mechanical integration for new production lines.
- End-to-End Delivery
- Guaranteed Performance
Field Commissioning
On-site execution. Our field engineers conduct loop checks, SAT protocols, and operator training to ensure flawless startup.
- Site Acceptance Testing
- Production Ramp-up
Certified Vendor Integrations
As an independent systems integrator, we partner with the world's leading OEMs to design the right architecture for your exact production requirements.
PLCs & Logic
HMI, SCADA & Design
Motion & Drives
Industrial Networking
Our 5-Phase Engineering Lifecycle
We execute industrial automation projects with a rigorous, standard-aligned methodology that eliminates commissioning surprises.
FEED & Scoping
Front-End Engineering Design. We collaborate with plant managers to define User Requirement Specifications (URS) and budget constraints.
Detailed Design
Drafting functional design specifications, AutoCAD electrical schematics, and writing PLC/SCADA control logic.
Build & FAT
[X] panel fabrication followed by Factory Acceptance Testing (FAT)—simulating all I/O before shipping.
Install & SAT
On-site mechanical/electrical installation, loop checks, and Site Acceptance Testing (SAT) for seamless handover.
Lifecycle Support
Operator training, preventive maintenance SLAs, and continuous OEE monitoring to maximize your asset ROI.
Why Choose IntliEx for System Integration?
Unplanned downtime is the enemy of profitability. We engineer robust, compliant control systems built to keep your plant running 24/7/365.
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Downtime Minimization
We specialize in phased cutovers and targeted retrofits. We upgrade your control intelligence without requiring massive mechanical replacements or extended plant shutdowns.
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Rigorous FAT & SAT Testing
We find the bugs in our fabrication shop, not on your plant floor. Every system undergoes extensive hardware-in-the-loop simulation (FAT) before it ever ships to your site.
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Objective OEM Independence
We aren't forced to push a single vendor's catalog. Whether your plant standard is Rockwell, Siemens, or Schneider, we engineer the optimal architecture for your specific process.
Ready to Get Started with Industrial Automation?
Discuss your specific requirements with our domain experts and discover how IntliEx can accelerate your goals.
- Expert Consultation
- Custom Architecture
- Scalable Solutions