We specialize in the integration and optimization of industrial control systems, focusing extensively on Human Machine Interfaces (HMIs) and Programmable Logic Controllers (PLCs).

Understanding HMI’s and PLC’s:
A Human Machine Interface (HMI) serves as the visual and control interface between the human operators and the machinery or process they are controlling. HMIs allow operators to monitor machine performance, view system status, and manage operations through graphical representations. On the other hand, a Programmable Logic Controller (PLC) is essentially the brain of the machine or process. It's a robust digital computer designed for the control of manufacturing processes, such as assembly lines, robotic devices, or other activities requiring high reliability control, ease of programming, and process fault diagnosis.

Programming Services:
Our expertise in programming HMIs and PLCs involves writing and optimizing code that dictates how these systems function. For PLCs, we employ ladder logic, function block diagrams, structured text, or other IEC 61131-3 languages depending on the application's complexity and client requirements. HMI programming includes creating user-friendly interfaces where operators can easily navigate through the system, initiate commands, and receive feedback. We ensure that every program is robust, efficient, and includes fail-safes for operational continuity.

Common Brands and Applications:
We are proficient with leading brands in the industry such as Siemens (S7 series), Allen-Bradley/Rockwell Automation, Omron, Panasonic, Phoenix Contact, and more. These systems are integral in numerous applications within manufacturing, ranging from automotive assembly, food and beverage processing, to pharmaceuticals where precision, speed, and safety are paramount. Our solutions help in enhancing production rates, improving quality control, and reducing operational costs through automation.

Challenges in Automation:
When companies undertake the automation of their plants, several challenges arise.

      •   Integration Complexity
Integrating new HMI and PLC systems with existing infrastructure often involves overcoming compatibility issues. Legacy systems might not communicate seamlessly with modern technology, requiring adaptive solutions.

      •   Skill Gaps
There's often a gap in the skill set required to handle modern automation tools. We provide training and support to ensure that your team can manage these systems post-installation.

      •   Customization Needs
Every manufacturing process has unique elements. Customizing HMI and PLC solutions to fit specific operational needs while maintaining scalability can be complex. Our approach is to design systems that are not only functional for current needs but also adaptable for future expansions.

      •   Cybersecurity
With increased connectivity comes the risk of cyber threats. We incorporate security protocols from the design phase to protect sensitive manufacturing data and ensure system integrity.

      •   Cost Justification
Initial investment in automation can be significant. We assist clients in understanding the long-term ROI, detailing how automation can lead to energy savings, increased production yield, reduced downtime, and lower labor costs.

Our commitment at Shadowalk Automation is to navigate these challenges with you, leveraging our deep industry knowledge to deploy HMI and PLC systems that enhance efficiency, safety, and profitability. We pride ourselves on delivering tailored solutions that align perfectly with your operational goals, ensuring a smooth transition into the benefits of modern automation.

What is SCADA?
Supervisory Control and Data Acquisition (SCADA) systems are integral to the operation, management, and automation of industrial processes. SCADA systems provide a centralized platform for monitoring and controlling various components of a manufacturing plant in real time. They collect data from sensors and instruments across the facility, allowing operators to oversee, adjust, and manage operations from a single location. This technology is pivotal in industries like manufacturing, where precision, efficiency, and immediate responsiveness to operational changes are crucial.

Challenges with SCADA in Manufacturing Plants
While SCADA systems are highly beneficial, they come with their set of challenges.

      1.   Integration Complexity
Integrating SCADA with existing plant machinery, especially older equipment, can be complex. Different systems might use varied communication protocols or software, requiring custom interfaces, converters, or upgrades.

      2.   Data Management
Handling the vast amounts of data generated by SCADA systems for effective analysis and decision-making can be overwhelming. Ensuring data integrity, security, and real-time access is crucial but challenging.

      3.   Cybersecurity Risks
As SCADA systems are often connected to the internet for remote monitoring and control, they are vulnerable to cyber threats. Protecting these systems from unauthorized access and ensuring the security of operational data is a significant concern.

      4.   System Reliability and Downtime
SCADA systems must be highly reliable. Any downtime can lead to significant production and data losses. Ensuring continuous operation, even during software updates or hardware replacements, is a key challenge.

Our SCADA Solutions
At our company, we specialize in overcoming these challenges with comprehensive SCADA services.

      •   Custom Integration
We evaluate your current infrastructure to design a SCADA integration strategy that minimizes disruption and maximizes compatibility. Our team has expertise in various SCADA platforms and can tailor solutions to fit your specific needs, ensuring smooth communication between new and legacy systems.

      •   Data Management and Analytics
We implement advanced data management solutions that not only collect and store data but also provide analytical tools for real-time insights. This includes setting up dashboards, trend analysis, and predictive maintenance algorithms to help you make informed decisions.

      •   Enhanced Cybersecurity
We prioritize your system's security by implementing robust cybersecurity measures. This includes network segmentation, securing remote access, regular security audits, and compliance with industry standards like ISA/IEC 62443 for industrial automation and control systems.

      •   Reliability and Maintenance
Our service includes the design of fault-tolerant systems, where redundancy is built into critical components. We also offer continuous support and maintenance plans that ensure your SCADA system operates with minimal downtime. Our updates and upgrades are managed with strategies that prevent operational interruptions.

      •   Training and Support
We understand that technology evolves, and so does the skill set needed to manage it. Therefore, we provide comprehensive training for your staff on how to operate and maintain the SCADA system, along with ongoing technical support.

By choosing our services, manufacturing plants can expect not only an efficiently running SCADA system but also a strategic partner committed to enhancing operational capabilities, ensuring compliance, and safeguarding against potential disruptions.

Our company is deeply embedded in the landscape of automation software, providing extensive support and integration solutions across several leading platforms in the controls and automation industry.

      •   Rockwell Automation Software
We are well versed in Rockwell’s PLC and drive programming tools including Studio 5000, RSLogix 5000, RSLogix 500, and Connected Components Workbench giving us the tools to service any product series made by Allen Bradley. We leverage Rockwell's FactoryTalk suite, which includes FactoryTalk View for HMI and SCADA applications, FactoryTalk AssetCentre for asset management, and FactoryTalk Historian for data logging. These tools are designed for high interoperability with Rockwell's ecosystem, ensuring smooth data flow and control operations. Our team is skilled in maximizing the potential of these tools, tailoring them to fit the specific operational strategies of our clients.

      •   Siemens Software
Siemens' TIA Portal (Totally Integrated Automation Portal) and WinCC are central to our offerings. TIA Portal integrates configuration, programming, testing, and diagnostics of all automation components in one engineering framework, simplifying the lifecycle management of automation systems. WinCC offers powerful SCADA and HMI capabilities, enhancing process visualization and control. Our expertise ensures these systems are efficiently implemented to enhance productivity through optimized software-to-hardware communication.

      •   Ignition by Inductive Automation
Known for flexibility, Ignition stands out with its universal connectivity, allowing it to interface with virtually any PLC, database, or industrial equipment. It uncovers previously hidden data and gathers it together to reveal enlightening trends which drive solutions. We utilize Ignition for its modular design, which supports SCADA, HMI, and IIoT applications across a variety of use cases and location types. These include enterprise and corporate deployment, broad facility and process monitoring, and remote location management. We excel in crafting custom applications in Ignition to bring our clients ideas to life, showcase their data in enlightening ways, and facilitate fast responses to events plantwide. Our solutions improve user efficiency by being not only functional but intuitive, and we build with an adaptive design which scales with the growth of our client’s business.

      •   Custom Software Solutions
Understanding that off-the-shelf software might not fully meet every client's needs, we specialize in developing custom software. This includes SCADA systems, custom desktop applications, specialized data analysis tools, or unique control algorithms. Our custom solutions are designed to integrate seamlessly with existing software, ensuring that they augment rather than complicate the automation landscape.

Our commitment is to ensure that all software solutions not only meet but exceed industry standards, providing clients with systems that are reliable, secure, and tailored to their operational objectives. We aim to optimize software performance, ensure compatibility across different platforms, and facilitate smooth software-to-hardware integration for maximum operational efficiency.

Our company not only develops and maintains software solutions, but also integrates and works with a comprehensive array of hardware systems designed to enhance operational efficiency and accuracy in manufacturing environments.

      •   RFID & Barcode Scanners
Radio Frequency Identification (RFID) technology plays a crucial role in asset tracking, inventory management, and workflow automation. We implement RFID systems that can read tags without line-of-sight, allowing for real-time data capture about product movement, location, and status.
Barcode scanners have become nearly flawless at capturing codes due to modern technological advancements and they are used extensively in most manufacturing and distribution processes. We are knowledgeable about many types of high quality scanners and ready to support new implementations and existing system upgrades.
These technologies reduce human error, speed up processes like receiving and shipping, and provide invaluable data for analytics and operational optimization.

      •   Measurement Instrumentation
Measurement tools, including pressure, temperature, flow, and level sensors, are integral to our control systems. These devices are renowned for their precision and reliability, crucial for maintaining process control in industries requiring exact measurements. We integrate smart transmitters and analyzers to ensure that manufacturing processes run within specified parameters, enhancing safety, quality, and efficiency. Their digital communication capabilities like Modbus, HART, Foundation Fieldbus, or Profibus allow for seamless integration into our SCADA and control systems, providing detailed diagnostics and predictive maintenance insights. We provide specification of industry standard measurement instruments engineered by brands such as Emerson, Schneider Electric, Krohne, Burkert, Honeywell, ABB and many more.

      •   Optical Identification Systems
Optical identification, including barcode readers and vision systems, are key for quality control, product verification, and traceability. We employ advanced vision systems that can perform high-speed inspections, detect defects, verify labels, or ensure correct assembly. These systems can be configured to interface with our automation software, enabling the system to make real-time decisions or adjustments based on visual input. This technology is particularly useful in high-volume manufacturing where manual inspection is impractical.

      •   Control Valves and Actuators
For processes requiring fluid or gas flow control, we incorporate control valves from companies like Fisher (Emerson), Masoneilan (GE), or Samson. These valves, paired with actuators, allow for precise regulation of material flows, which is critical in industries like chemicals, oil & gas, and pharmaceuticals.

      •   Safety Systems
We also work with safety instrumented systems (SIS) and emergency shutdown systems (ESD) to ensure compliance with safety standards like IEC 61511/SIL. These systems are crucial for operations where human or environmental safety is paramount.
Our approach to hardware integration involves not just the selection and installation but also the optimization of these devices within the broader context of plant automation. We ensure that all hardware communicates effectively with our SCADA and control software, providing a comprehensive solution that meets the client's operational, safety, and efficiency requirements. This holistic integration allows for a system where hardware and software work in concert to achieve maximum productivity and control.

At our company, we offer specialized solutions to enhance plant productivity through comprehensive assessment, management, and data collection strategies. Our productivity assessment involves deploying advanced analytics tools that analyze operational data to identify bottlenecks, inefficiencies, and areas for improvement. We utilize key performance indicators (KPIs) like Overall Equipment Effectiveness (OEE), production rates, downtime analysis, and quality metrics to provide a clear picture of how well a plant is performing against its objectives. Our team then crafts tailored recommendations that could involve process optimization, equipment upgrades, or changes in workflow. This service not only helps in pinpointing where productivity can be enhanced but also in setting benchmarks for continuous improvement.

For management, server initialization, and data collection, we provide robust systems that ensure seamless operation and data integrity. We initialize servers with state-of-the-art software environments designed for industrial applications, ensuring they are optimized for high availability, scalability, and security. Our data collection solutions incorporate both traditional sensors and IoT devices to gather real-time data from the shop floor. This data is then streamlined through our data management platforms or integrated into industry-standard systems like those from Siemens or Rockwell for storage, analysis, and visualization. We implement automated data logging systems that minimize manual entry errors, enhance data accuracy, and facilitate real-time monitoring. This setup allows plant managers to have immediate access to critical operational data, enabling quick, informed decision-making for productivity enhancements, predictive maintenance, and quality control.

Our company offers tailored solutions to optimize plant operations, ensuring they run more effectively and efficiently. We specialize in Batch & Recipe Management, where we introduce sophisticated software solutions that meticulously manage the formulation, execution, and documentation of production recipes. These systems are crucial for industries where product consistency is paramount, like pharmaceuticals, food processing, and specialty chemicals. Our batch management solutions not only automate the process but also provide traceability, which is essential for compliance with regulatory standards and for maintaining high-quality control.

Additionally, we provide comprehensive Employee Training programs. Recognizing that the human element is as critical as the technological one, our trainings are designed to bridge knowledge gaps and enhance operational understanding. Training ranges from basic operator skills to advanced troubleshooting and maintenance of automation systems.

Other services include Performance Monitoring and Optimization where we continuously analyze data from plant operations to provide insights that drive improvements. This can involve everything from energy consumption patterns to machine efficiency, aiming to reduce costs and increase throughput.

Our company recognizes the value of legacy software and hardware in many manufacturing environments, where reliability and longevity are often more important than the latest technological advancements. We provide specialized services to ensure these systems continue to serve effectively while adapting to modern requirements.

      •   Legacy System Maintenance
We offer comprehensive maintenance services for older automation systems, which include regular checks, updates, and repairs to keep them running efficiently. Our technicians are skilled in handling equipment that might be out of production or no longer supported by the original manufacturer. This involves sourcing parts, where possible, or developing workarounds to extend the life of these systems. We also perform preventive maintenance to preemptively address wear and tear, ensuring minimal downtime and extending the operational life of the equipment.

      •   Software Upgrades and Compatibility
Many legacy systems run on software that's outdated or no longer supported. We assist in upgrading these systems to newer versions or finding compatible versions that can still interface with existing hardware. For software that cannot be updated, we develop or source custom patches or interfaces. This might involve writing software drivers, emulators, or gateways to allow legacy systems to communicate with new software environments or to integrate with modern IT systems for data collection and analysis.

      •   Integration of New with Old
When new hardware or software needs to be introduced, we focus on seamless integration. This can mean configuring new control systems to work with old machinery or ensuring that new sensors can feed data into an old SCADA system. We provide solutions like OPC servers or protocol converters to bridge the gap between old and new technologies, ensuring that the plant can benefit from advancements without a complete overhaul.

      •   Cybersecurity for Legacy Systems
Older systems can be particularly vulnerable to cyber threats due to outdated security measures. We assess these systems for potential vulnerabilities and deploy measures like network segmentation, security patches where available, or even air-gapping to protect critical systems from external threats. Additionally, we might suggest controlled and secure internet access for these systems, enabling remote monitoring while minimizing exposure.

      •   Performance Optimization
Even legacy systems can benefit from optimization. We analyze the performance of these systems, looking for inefficiencies that can be remedied. This might involve fine-tuning control loops, optimizing batch recipes, or improving the efficiency of data collection to make the most of what the old equipment can offer.
Our approach to servicing, maintaining, and upgrading legacy systems is rooted in understanding the intricate details of each plant's setup. We aim to preserve the functionality and safety of your operations while allowing for gradual modernization, ensuring that your plant remains competitive without the need for disruptive and costly full-scale replacements.