Automation and Controls Retrofits
THG retrofits legacy equipment with PLC and DSI control, recipe-driven setpoints and the instrumentation to see what the line is doing. The work starts with an assessment of the existing system and ends with commissioning against the agreed operating requirements.
How a Controls Retrofit Runs
1. Audit what is there
Review the panels and drawings, trace the sensors and document the existing control scheme before defining the retrofit.
2. Define the recipes
What the line has to make, and the setpoints each product needs. This comes from your operators.
3. Design the retrofit
PLC, DSI and the instrumentation to see what the equipment is doing, with a clear line between what has to be replaced and what can stay.
4. Install and integrate
Panel built, PLC installed, sensors placed, and the whole system tied into the equipment that is already running.
5. Commission and verify
Run every recipe, and confirm the setpoints hold and the readings match what the line is actually doing.
Scope of Work
- Audit of existing controls, panels, wiring and instrumentation
- PLC retrofits on legacy equipment
- DSI (direct spark ignition) control
- Recipe-driven setpoints, one recipe per product
- Instrumentation and sensor placement, so the line can be measured rather than guessed at
- Panel build and integration with the existing line
- Commissioning against every recipe before handoff
Why THG
We know the mechanical side
The assessment covers the equipment as well as its controls, including the burners, drives and sensors that affect how the line runs.
Retrofit, not replace
We work out which panels, instruments and controls need replacing and which components can stay.
Instrumented, not blind
A line that runs blind can’t be optimized. The point of the retrofit is that you can see what it is doing.
Industries Served
Common questions
Do I have to replace the whole line?
Usually not. Retrofitting legacy equipment with modern control is the core of this work, and we scope what has to go and what can stay.
What does recipe-driven control get me?
One recipe per product, with setpoints that hold, so results stop depending on which operator is running the line that shift.
Why go to a mechanical shop for controls?
The assessment covers both the control system and the equipment it runs, which shows whether the fix belongs in the panel, the mechanical system or both.
Can you work on controls for equipment you did not build?
Yes. We audit what is there first, whoever put it there.
Tell us about the work.
Start with the equipment, the site and the work you need done. Line down now? Call 800-356-7591.