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Automated Control Systems

BMI designs, builds, and installs automated process control systems and industrial communications network architectures for production facilities. BMI’s process engineers collaborate with our customers and equipment suppliers to ensure our automated control systems and network architectures deliver predictable batch processing consistency.  We combine market leading software and hardware, with our process expertise to provide the best solutions for your application. BMI’s system automation engineers and process engineers work together from the beginning of concept development through the final stages of commissioning. This collaboration delivers a cohesive, automated, and truly turnkey process design.


BMI has designed and implemented hundreds of automated process systems including:

  • Greenfield process solutions
  • Standalone, skid mounted and distributed control systems
  • Integration of new equipment to legacy systems
  • Systems requiring continuous processing with no downtime

Our systems automation engineering team provides:

  • 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

Process controls and automation impacts your bottom line by:

  • 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 to an increase in production performance.

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

Read what the Vice President of Production for Gekkeikan Sake USA, Inc. has to say about BMI

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

We put safety first

At BMI we know putting safety first protects our employees and customers, while improving our productivity, competitiveness, and profitability. We incorporate food safety into our process designs and worker safety is a continuous effort overseen by our safety management team. In addition to the financial benefits and increased productivity, the minimization of on-the-job injuries results in a bigger payoff – our employees’ ingrained commitment to food and jobsite safety.

We have an extensive safety program and an outstanding safety record

Our systems adhere to 3-A sanitary design, FDA, FSMA, USDA, ASME, OSHA and UL regulations. Our project managers and foremen are OSHA 30 certified and conduct daily job hazard analysis (JHA), job safety analysis (JSA) meetings, and weekly team safety meetings. Our skilled journeymen are OSHA 10 certified and trained to adhere to our high safety standards.


Our proactive approach is reflected in our outstanding safety record. In our more than 40 years of operation, our .66 experience modification rate (EMR) has consistently surpassed the industry average of 1.0.

You know your products. We know process

BMI is an industry leading full-service design-build company specializing in next generation solutions for the food, beverage, specialty process, and other sanitary industries. Since 1980, our team of design engineers, automation and controls engineers, project managers and expert installers provide unsurpassed value and results. Regardless of the scale or complexity of the project, we deliver the right technology and automation solutions for high-performance sanitary processing and production. BMI is headquartered in Northern California and operates throughout the United States.  BMI is an American-owned and privately held company.

Contact Barnum Today Call 800.922.7686