Controllynx
Automation Projects
1. Water Treatment Plant Upgrade
2. Conveyor Handling System in Mining
3. HVAC Automation for Commercial Facility
4. Food Processing Plant Modernization
5. Municipal Wastewater Pumping Station
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Water Treatment Plant Upgrade
Client Challenge
A regional water utility operated a 25-year-old treatment facility that relied on outdated relay logic and standalone instrumentation. Operators had no centralized monitoring and had to physically check pumps, dosing systems, and filtration equipment. This led to inconsistent water quality, delayed responses to faults, and frequent downtime.
Our Proposal
We performed a detailed site audit and presented a modernization plan that included migrating to a PLC-based system with centralized SCADA. Unlike competitors who suggested a full rip-and-replace approach, we recommended a phased migration to minimize downtime. Our proposal also emphasized regulatory compliance and improved water quality reporting, which were key to securing the contract.
Solution Delivered
* Installed Siemens PLCs with modular I/O to accommodate 300+ signals.
* Integrated chemical dosing skids, filters, and pumps into a single SCADA platform.
* Added redundancy to critical pumps with automatic failover logic.
* Conducted commissioning in phases to ensure uninterrupted water production.
Result
The utility achieved 25% downtime reduction, consistently met water quality standards, and gained remote visibility of the entire treatment process.
Conveyor Handling System in Mining
Client Challenge
A mining client operated 8 conveyor lines to transport ore, but the system frequently suffered from overload trips due to uneven loading. Operators had no real-time visibility of load distribution, causing costly stoppages in production.
Our Proposal
We proposed upgrading the system with belt scale monitoring and load-balancing logic. Competing vendors offered monitoring-only solutions, but our emphasis on real-time corrective action via VSD control convinced the client to award us the project.
Solution Delivered
* Installed belt weigh scales on each conveyor with PLC integration.
* Developed PID-based load distribution logic.
* Integrated VSD control for smooth ramping and energy optimization.
* Provided SCADA dashboards for operators to track loading in real time.
Result
Throughput improved by 18%, unplanned stoppages were reduced by 30%, and maintenance costs declined due to less mechanical stress on equipment.
HVAC Automation for Commercial Facility
Client Challenge
A commercial building relied on manually operated AHUs, VAVs, and chillers, resulting in excessive energy usage and poor occupant comfort. Facility managers lacked data on airflow, temperatures, and damper positions, making optimization impossible.
Our Proposal
We proposed automating the HVAC system with PLCs and SCADA integration. Our proposal included demand-based ventilation and occupancy scheduling, which competitors had overlooked. This focus on energy savings helped us secure the project.
Solution Delivered
* Automated 12 AHUs, chillers, and 80+ VAV terminals.
* Implemented temperature and CO₂-based demand ventilation control.
* Installed SCADA dashboards for energy monitoring and fault alerts.
* Commissioned the system with staged cutovers to avoid disruptions.
Result
Energy usage dropped by 22% in the first year, indoor comfort levels improved, and the building achieved a higher green energy rating.
Food Processing Plant Modernization
Client Challenge
A food manufacturer was still using relay-based control panels for their batch processing line. The system lacked data logging, had inconsistent batch quality, and was difficult to maintain. Shutdowns for even small failures were frequent.
Our Proposal
We presented a plan to migrate the system to PLC + SCADA with minimal disruption. Unlike competitors who proposed shutting down the entire plant for two weeks, we proposed simulation-based testing and phased commissioning, which convinced the client to award us the project.
Solution Delivered
* Developed PLC code to automate dosing, mixing, and heating sequences.
* Designed HMI screens for operators to monitor and adjust recipes.
* Implemented historian logging for quality assurance.
* Commissioned new logic in phases during off-production hours.
Result
Batch consistency improved by 15%, downtime was reduced to near zero, and quality reporting enabled compliance with food safety standards.
Municipal Wastewater Pumping Station
Client Challenge
The municipality operated multiple remote pumping stations but had no centralized monitoring. Operators had to physically check sites daily, and emergency failures at night often went undetected for hours, leading to costly overflows and environmental fines.
Our Proposal
We proposed installing PLCs with GSM alarm capability and integrating all stations into a centralized SCADA system. Competing bidders offered only SCADA integration without field-level upgrades. Our approach of combining field automation with remote monitoring won us the contract.
Solution Delivered
* Installed PLCs with GSM-based alarm dialers at each pumping station.
* Configured central SCADA with live pump status and trend analysis.
* Set up auto-callouts for high level alarms, pump trips, and power failures.
* Provided training for municipal operators on new monitoring tools.
Result
Emergency callouts were reduced by 40%, average response time improved from 2 hours to 20 minutes, and environmental compliance penalties dropped significantly.