Automated Control Systems

Navigating Automation

BMI specializes in crafting state-of-the-art automated process control systems and industrial communication networks tailored for production environments. Our approach is collaborative and client-centric, involving a seamless partnership between our control and process engineers, clients, and equipment vendors. This synergy ensures our automated control systems and network solutions consistently deliver optimal batch and processing results.

Our expertise lies in integrating leading-edge software and hardware with our in-depth process knowledge, ensuring every solution we provide is perfectly suited to your specific application needs. From the initial concept development to the final stages of commissioning, BMI's team of system automation and process engineers work in unison. This collaborative process results in a unified, automated, and turnkey process design which is tailored to your operational needs.

Key Components of Our Automated Controls Services

  • Greenfield process solutions
  • Standalone, skid mounted and distributed control systems
  • Integration of new equipment to legacy systems
  • Systems requiring continuous processing with no downtime
  • Automated control system engineering, installation, project management, commissioning and validation
  • Functional industrial network architecture design
  • Electrical system engineering and electrical installation management
  • Application-specific industrial Supervisory Control and Data Acquisition (SCADA) systems
  • Open system, scalable and cost-competitive equipment
  • Control panel hardware specification and procurement
  • Project management
  • PLC/PAC ladder, structured text, and function block programming
  • ENET/IP, CNET, DNET, AS-I, ModBus, and MQTT protocols
  • Allen Bradley, Siemens, GE, Modicon PLCS and many other brands
  • Standalone, skid-mounted, and distributed control systems
  • Fully documented PLC programming, graphical Human to Machine Interface (HMI), and SCADA application development
  • Factory acceptance tests (FAT)
  • System commissioning and validation
  • On-site customer training
  • Post installation remote and onsite controls support
  • Report development
    • Automatic and manually generated
    • Production
    • CIP
    • Inventory
    • Maintenance
  • Process alarm management
  • Predictive maintenance
  • Process optimization

Our team can provide new control systems or seamlessly integrate new functions into legacy systems for multiple process and utility systems, such as:

  • Raw, wet, dry and powder bulk ingredient handling, storage, and distribution systems
  • Batching systems
  • Blending systems
  • Complex valve manifolds
  • Mixproof valve assemblies
  • Thermal process and pasteurization systems
  • Hydration systems
  • Filtration systems
  • Clean-in-Place (CIP) systems
  • Clean-out-of-place (COP) systems
  • Sanitization/foam/rinse systems
  • Hot water support systems
  • Sanitary air systems
  • Steam/condensate handling systems
  • Compressed air systems
  • N₂, CO₂, Glycol and chemical systems
  • Water treatment systems
  • Reducing water consumption
  • Reducing chemical consumption
  • Maximizing process throughput and product quality
  • Increasing batch accuracy
  • Simplifying recipe changes and new recipe implementation
  • Improving sanitation and decreasing risk from contamination
  • Automating data collection
  • Ensuring process motors do not exceed their necessary frequency requirements
  • Reducing manpower
  • Reducing human errors
  • Monitoring overall equipment effectiveness
  • Sending predictive maintenance alerts to maintenance managers
  • Providing complete product genealogies
  • Providing automated reporting

Predictive maintenance

Automation systems can help reduce the total cost of equipment ownership by helping to predict when equipment will need repair or replacement. Asset management is critical in processing where advanced machinery is expensive. Depreciation is a key cost and major cost savings can be achieved by moving to predictive maintenance systems. A long-term predictive maintenance system is a cost-efficient strategy, contributing to a significant decrease of maintenance hours and spare parts expenses, and increasing production performance.

To read more about how predictive maintenance systems can reduce your costs, download our Delivering Uptime with Predictive Maintenance Systems whitepaper.


See What People Are Saying

“We’ve worked with Barnum Mechanical many times over the past 10 years. They have provided us with a high-level of skill in controls and electrical engineering, instrumentation configuration and trouble-shooting. Barnum has proven that they can systematically analyze a control system and fine tune the equipment until optimal performance is achieved. We value our relationship with them and will continue to rely upon them in the future.”

William Piper

Vice President, Production, Gekkeikan Sake USA

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