Process Control Systems

Here at S4 Engineering, we supply and install a wide range of integrated process control systems suitable for various applications, from raw material reception through to finished products. Learn more about what we do below, or speak to us today to discuss your project.

What We Do

The systems we supply provide optimum performance through data collection, batch reporting, traceability, monitoring and integration with higher-level database and office solutions.

Our software engineers also apply their expertise to automate and update existing systems. Combined with our own company’s full range of production equipment, this allows us to provide comprehensive solutions to suit every requirement.

Our software engineers have extensive experience working with PLCs and SCADA/HMI-based control systems, including:

  • Siemens: S5, S7, TIA Portal, Simatic Manager and WinCC (PLC, SCADA and HMI)
  • AVEVA Solutions: System Platform, InTouch HMI (SCADA and HMI)
  • Rockwell Allen Bradley: ControlLogix, CompactLogix, Studio 5000, FactoryTalk View SE + ME (PLC, SCADA and HMI)
  • Inductive Automation: Ignition SCADA (SCADA)
  • Mitsubishi: MELSEC, GX, MX, FX (PLC)
  • OMRON: Cx, Nx (PLC and HMI)
  • CODESYS Automation Platform (Generic PLC software)

Our PLC control panels are built using parts from leading manufacturers, including Rockwell, Siemens, GE, ABB and Schneider/Merlin Gerin. 

Contact Us

The Installation Process

  • The process begins with a consultation, after which we receive or support the generation of a Functional Design Specification (FDS)
  • The bespoke control panel is designed using the latest version of the industry standard E-Plan CAD software
  • The designs are reviewed with the site team, and feedback is taken on board. We then make any necessary changes before getting final sign-off
  • Witnessed Factory Acceptance Tests (FAT) are then carried out on-site or at our facility prior to being delivered
  • The process is then finalised with the on-site installation of your new control panel
  • On completion of the installation, the commissioning and site acceptance test (SAT) will be carried out.

 

Benefits of Control & Automation

Benefits of adding automation to your recipe process control systems include, but are not limited to:

  • Improve accuracy and minimise errors on the production line to reduce scrap rates 
  • Reducing costs and site visits with remote troubleshooting access
  • Create a more efficient system that boosts productivity and output 
  • Make operations easier for your team to manages

Packages We Offer

Standard Control Package

This comprehensive recipe and reporting package provides you with the tools to create, manage and consistently manufacture your products. It also provides your customers with reports to confirm that process and quality requirements were met.

Flexible enough to meet your future needs, this package also integrates with higher-level SCADA and MES packages.

It includes:

  • Recipe solutions to assist users in carrying out the manufacturing procedures of our cooking vessels, such as adding bulk ingredients like water, adding major ingredients by way of a bin tipper and adding minor ingredients through a manway. This also includes agitating the vessel content, mixing (high shear) the vessel contents, heating using jacket and/or steam injection, discharging the final product, and cleaning the equipment (CIP).
  • A control system to run the mechanical and process equipment from an electrical panel, which houses an industry-standard programmable logic controller, an I/O termination system, local networking infrastructure and a human-machine interface screen.

 

Advanced Control Package

The advanced package improves on the standard version in the following ways:

  • The recipe editor is handled on a server-based SCADA system and SQL database using standard Ethernet networking connectivity.
  • The reporting extension seamlessly handles direct and automated reporting to the server-based SCADA system and SQL database.
  • The advanced control package includes servers, workstations, monitors, keyboards, mice and all necessary software licences.

 

Find Out More

Speak to our team for more information about our process control solutions and how we can support your operational goals.

Speak to Our Team

Innovation


Research & Development is at the forefront of our business strategy.

Safety


Our company culture is fundamental to our safety policies and wellbeing of our teams.

Value for Money


S4 provides value for money, while delivering quality, sustainable solutions.

Customer Trusted


Our people and the values we follow make S4 Engineering the customer's choice.

Quality Solutions


We offer pragmatic solutions and improvements tailored to the customer’s needs.

Our Customer Opinion

Darryl Stanley - Britvic Group Engineering Specialist

Darryl Stanley

Innovative and proactive company that understands the client requirements.

Darryl Stanley
Britvic Group Engineering Specialist
Peter Timotheou – Operations Director – Tims Dairy

Peter Timotheou

No hesitations in recommending S4 Engineering for the installation of
hygienic process plant and supporting systems.

Peter Timotheou
Operations Director – Tims Dairy
Matt Soden – Procurement Manager – 2SFG

Matt Soden

S4 Engineering is a Preferred supplier to 2SFG for all
liquid, cooking, cooling and process systems

Matt Soden
Procurement Manager – 2SFG

Process Control Systems Case Studies

Hain Daniels

Our engineers visited the plant of Hain Daniels, one of the UK’s leading food companies, to install a trio of bespoke 1,000 litre stainless steel pressurised kettles. The £2.5m contract also included the installation of associated control systems and pipework.

Read Full Case Study

Related Services

Do your process control systems feature remote access?
Yes, remote access systems can be installed with our process control systems. We currently support many customers around the world remotely, reducing the need for site visits and keeping costs down. The installation of a remote access system can be carried out with very little disruption to existing systems and is offered as an option on all new projects.
What features do your process control systems have?
Our process control systems come with various useful features and functions, including: - Plant visualisation - Real-time display of temperatures, flow rates, pressures and conductivity - Easy-to-observe overview of plant or equipment operations - Batch interface - Reporting interface - Alarm and event interface - Historical trending interface - Recipe management interface - Recipe storage
Which areas do you cover?
We cover the entire UK and often complete work for overseas customers.