THG services

Automation & Controls

Retrofit legacy equipment with PLC, DSI, recipe-driven controls, and instrumentation.

Operator controls and guarded conveying equipment
Operator controls and guarded conveying equipment

Automation & Controls at THG

We retrofit legacy equipment with PLC and DSI control, recipe-driven setpoints, and instrumentation. The work starts with an assessment of the existing system and ends with commissioning against the agreed operating requirements.

The process

How it works

  1. Audit what is actually there

    Review panels and drawings, trace sensors, and document the existing control scheme before defining the retrofit.

  2. Define the recipes

    What the line has to make, and what setpoints each product needs. This comes from your operators, not from us.

  3. Design the retrofit

    PLC, DSI, and the instrumentation to see what the equipment is doing. We scope what has to be replaced and what can stay.

  4. Install and integrate

    Panel built, PLC installed, sensors placed, and the whole thing tied into the equipment that is already running.

  5. Commission and verify

    Run every recipe. Confirm the setpoints hold and the readings match what the line is actually doing.

Scope

Scope of work

Discuss the items your project needs. Final scope is confirmed with your quote.

  • Audit of existing controls, panels, wiring, and instrumentation.
  • PLC retrofit on legacy equipment.
  • DSI control.
  • Recipe-driven setpoints, one recipe per product.
  • Instrumentation and sensor placement so the line can be measured, not guessed at.
  • Panel build and integration with the existing line.
  • Commissioning against every recipe before handoff.
Shop & field experience

Shop experience. Field support.

We know the mechanical side

We assess the equipment as well as its controls, including the burners, drives, and sensors that affect line operation.

Retrofit, not replace

We assess which panels, instruments, and controls need replacement and which existing components can remain.

Instrumented, not blind

A line that runs blind is a line you cannot optimize. The point of the retrofit is that you can finally see what it is doing.

FAQ

Automation & Controls: common questions

Do I have to replace the whole line?

Usually not. Retrofitting legacy equipment with modern control is the core of this work. 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. You stop relying 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 operates. That helps define whether the work 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.

Discuss automation & controls.

Share your drawing, equipment details or the issue on your line. We’ll review the scope with you.