Case Studies

DelaControl designed, built, tested and delivered a fully specified Motor Control Centre (MCC) for a UK minerals processing operation, incorporating a Siemens S7-1500F safety PLC, intelligent soft starters, a variable frequency drive, ET200SP distributed I/O, and bespoke TIA Portal software — all within a Form 4 Type 3 Rittal enclosure rated at 630 A.

DelaControl designed, built, and installed dedicated safety control panels for three cupper presses at a UK packaging facility, upgrading the safety guarding circuits to Performance Level e (PLe) in accordance with ISO 13849-1. The project covered all three press lines, each receiving a bolt-on enclosure housing new safety components, lockable guard switches, and a standstill monitor, with on-site installation carried out by DelaControl engineers.

DelaControl designed, built, and programmed a Siemens-based main control panel for a modular industrial liquid filtration machine. The system was engineered to manage up to four filter skids from a single control enclosure, with VFD-controlled pumps, safety PLC, HMI, UPS, and integrated power monitoring — all factory-tested before delivery.

DelaControl designed, built, and programmed a pair of PLC control backplates to manage circuit protection devices across Low Voltage and High Voltage switchboards in a commercial building services installation. The scope covered the full delivery: hardware, software, electrical design, thermal analysis, testing, and FAT.

DelaControl designed and built a new remote I/O junction box and carried out modifications to an existing main PLC control panel to bring eight additional cooler rooms under automated control at a UK food production site. The scope included PLC software updates, full electrical design, supply of field instrumentation, site installation, and commissioning.

DelaControl designed and built a full replacement control system for an obsolete line decorator at a UK packaging manufacturing site, including a new Allen-Bradley ControlLogix-based control panel, remote I/O panels, operator console, a 90 kW PowerFlex 755 drive, and a Pilz PNOZmulti 2 configurable safety system. Following build and commissioning, DelaControl also produced a formal Safety Design Substantiation Report (DSR) assessed against ISO 13849-1:2023, covering seventeen defined safety functions, and carried out on-site functional validation of the complete safety system.

DelaControl designed, built, and tested a large multi-section high-current power distribution panel for a marine survey services organisation, providing switched and protected distribution of power across multiple high-current circuits serving hydraulic power units, compressors, and ancillary equipment aboard a vessel support installation.

DelaControl designed, built, and commissioned a replacement control system for a tyre manufacturing machine, migrating the control platform from obsolete legacy Siemens equipment to a modern Siemens S7-1500T CPU with SINAMICS S120 servo drives and ET 200SP distributed I/O. The project included a fully engineered new control panel, bespoke PLC and motion control software, a full documentation package, factory acceptance testing, and site installation and commissioning.

DelaControl designed and built a suite of ten distinct control panel and backplate types — 31 units in total — to support the disc-mounted electrical systems of a high-performance racing simulator. The panels were built and tested at DelaControl's Bristol facility to IEC standards, with a full documentation package including electrical drawings, thermal calculations, and a Declaration of Conformity.

DelaControl built a batch of chiller and heater control panels to an existing customer design, with all wiring and cable specified in Low Smoke Zero Halogen (LSZH) materials in line with nuclear sector requirements. Panels were built, point-to-point verified, and presented for Factory Acceptance Test at DelaControl's Bristol facility.

DelaControl delivered a full control system engineering service for a specialist engine test rig, covering concept design, detailed electrical design, software requirements definition, control panel build, and safety engineering support. The project was structured to align with the customer's formal system gate review process, with DelaControl providing engineering continuity from initial concept through to detailed design and safety assessment.

DelaControl designed and built a comprehensive conveyor control system comprising a main floor-standing control panel, 27 individual VFD panels, and 45 operator control stations, complete with PLC software, HMI, and a full documentation package for a UK distribution facility.

DelaControl designed, built, programmed and commissioned a bespoke automated test system for a GNS measurement device, replacing a legacy tester that was no longer available or supported. The system included a Siemens PLC-based control panel, PLC and HMI software, a bespoke PWM signal conditioning PCB, and on-site commissioning to integrate the tester with the customer's network infrastructure and data logging systems.

DelaControl designed, built, and commissioned two independent control panels — one for a winding machine and one for a forming system incorporating a robot cell — together with all associated PLC and HMI software, documentation, and site acceptance testing, for a UK OEM automation integrator.

DelaControl designed, built, programmed and tested two bespoke control panels for a servo press unit and a hot drop unit, delivering a complete control system including safety-rated I/O, servo drive integration, PLC and HMI software, a Software Design Specification, and a full documentation pack.

DelaControl designed, built, programmed and tested a complete control system for a 50kW PEM electrolyser, delivering a Siemens S7-1500F safety PLC, a 10-inch Siemens Unified Comfort HMI panel, bespoke PLC and HMI software, and a pre-configured HMI laptop running WinCC Runtime — all from a single Rittal IP55 enclosure built and tested at DelaControl's Bristol facility.

DelaControl designed, built, and supplied six industrial control panels for a DeStacker ReStacker automated handling system — three panels certified to European CE requirements and three to American UL508A, allowing the same machine architecture to be deployed in both markets. The panels were built around an Allen Bradley CompactLogix 5380 PLC with distributed 1734 POINT I/O, PowerFlex 525 variable frequency drives, and a Kinetix servo drive, all housed in Rittal enclosures.

DelaControl designed, built, and commissioned a powered weighing conveyor system for a UK tyre processing facility. The scope covered mechanical fabrication of the conveyor frame, installation and wiring of four load cells, and a bespoke Siemens S7-1200 control panel with SIWAREX weighing module — together with PLC software to process weight data and communicate it to an existing transport management system.

DelaControl designed and built a standalone mimic control desk system for a UK defence engineering organisation, replicating an operational control system for training purposes. The system uses Siemens ET 200SP distributed I/O and a Siemens S7-1200 PLC, communicating with an external training environment controller via DMX protocol, and was supplied complete with custom mechanical layouts, a full electrical drawing pack, FAT, and site installation support.

DelaControl designed, built, and commissioned a complete control system for a large hand curler machine at a UK tolerance ring manufacturing site. The scope covered a Siemens S7-1212FC safety CPU with ET 200SP remote I/O, a Sinamics S210 servo drive, a 10-inch Unified HMI panel, PLC and HMI software, a full documentation pack, factory acceptance testing, site installation, and commissioning.

A UK manufacturing business needed to replace the obsolete control systems on two industrial furnaces. DelaControl designed, built, programmed, and commissioned two new Siemens-based control panels — one for each furnace — incorporating a Safety PLC, touchscreen HMI, remote access capability, and a formal risk assessment, with site installation and commissioning carried out by DelaControl engineers.

DelaControl delivered a full control system obsolescence upgrade for an industrial waste incineration facility, replacing an end-of-life Siemens S7-300 platform with a current S7-1500 F-CPU, migrating the existing Step 7 5.5 PLC software to TIA Portal, and rebuilding the supervisory SCADA system from Wonderware InTouch to Siemens WinCC. The scope covered hardware build, full documentation, factory acceptance testing, site installation, commissioning, and operator training.

DelaControl designed, built, programmed, and commissioned a Performance Level D safety control system to interlock a scissor lift platform and access door against the status of two access gates at a UK food production facility.

DelaControl delivered a software-only obsolescence upgrade for four instances of a Type 45 control system, migrating aging Allen Bradley PLC and HMI software to a modern Studio5000 and PanelView 5310 platform, with on-site verification support included.

DelaControl undertook the electrical design and documentation for the control system of an industrial abatement unit, redesigning the existing panel to achieve compliance with IEC 60204 and IEC 61439, and providing a clear pathway to NFPA 79 compliance for the US market. The scope included a full drawing pack, compliance documentation, and the supply and build of panel backplates.

DelaControl designed, built, programmed and commissioned the full electrical control system for a two-station automated OpticLine machine for a special purpose machine OEM. The scope covered two control panels, PLC and HMI software, ABB robot programming, Festo pneumatic manifold integration, full safety documentation including BS EN ISO 12100 risk assessment and BS EN 13849-1 SISTEMA report, Factory Acceptance Testing, mechanical cell build and on-site commissioning.

DelaControl designed and built a large batch of Beckhoff-based local control cabinets across two machine lines for a major tobacco manufacturer. Working to the customer's own electrical and mechanical designs, DelaControl procured materials, fabricated and assembled bespoke metalwork, and carried out full panel build and testing at its Bristol facility — delivering a complete, FAT-ready set of enclosures compliant with the Low Voltage and EMC directives.

DelaControl designed, built, programmed, and commissioned a complete replacement control system for an industrial electric motors panel, migrating to a modern Siemens S7-1500F PLC platform. The scope covered everything from electrical design and panel build through to PLC and HMI software, factory acceptance testing, site installation, and a subsequent panel upgrade to accommodate a higher-rated mixer motor.

DelaControl designed and built two fully integrated control systems for an OEM specialising in can manufacturing line equipment — one for a Pin Oven and one for an Internal Bake Oven. Each system was built, software-loaded, and factory acceptance tested at DelaControl's Bristol facility before delivery.

DelaControl designed and built three control systems for a set of can manufacturing line machines — a washer with integrated tornado, a pin oven, and an internal bake oven — delivering a fully tested, documented package ready for factory acceptance and deployment.

DelaControl designed, built and programmed a bespoke automated test rig to verify the integrity of a compressor controller destined for use in a nuclear facility clean air system. The project combined a Siemens S7-1500-based hardware enclosure with fully structured PLC software to exercise every input permutation of the controller under test, producing a fully auditable set of test results and a formal test report.

DelaControl designed and built a replacement control cabinet for a marine renewables OEM, intended for subsea installation. The scope included structural design improvements to address identified failure modes, full hardware build and test, mechanical manufacturing drawings, and a Factory Acceptance Test.

DelaControl designed, built, programmed, tested, and commissioned a main control panel to manage a multi-motor conveyor system, with all variable frequency drives housed within a single enclosure and full operator control provided from the panel door.

DelaControl designed and built a dual-bay electrical control panel for a thermal energy recovery system, incorporating Siemens variable frequency drives, a SIMATIC S7-1200 PLC with ET 200SP distributed I/O, a 12-inch comfort HMI, and an IIoT remote access gateway — all delivered with a full documentation pack and factory acceptance test.

DelaControl designed and built a Maker Breaker Control Panel for a marine equipment manufacturer, working to a customer-supplied drawing pack and delivering a fully tested, CE/UKCA-compliant panel with a Siemens ET 200SP distributed I/O assembly at its heart.

DelaControl designed, built, and commissioned a control system upgrade to integrate a Keyence machine vision camera system with an existing conveyor line at a UK food manufacturing facility. The solution replaced hardwired discrete I/O connections with an Allen-Bradley CompactLogix-based gateway, enabling the vision system to communicate over Ethernet I/P — and was fully tested at DelaControl's Bristol office prior to site installation.

DelaControl designed, built, programmed, and commissioned a new wall-mounted control panel housing a regenerative variable speed drive system to replace legacy drive equipment at a UK chemical processing facility. The panel integrates with an existing control system via hardwired I/O and is network-ready for future connection to a site-wide DCS.

DelaControl designed, built, and tested a main control panel and two VFD motor control boxes to provide variable-speed forward/reverse drive control and DOL bypass capability for a parcel conveyor system, delivering a complete panel package ready for site installation.

A customer operating a fleet of Air Treatment Units (ATUs) faced obsolescence of their existing York-platform controllers. DelaControl was engaged to develop replacement PLC and HMI software on a modern Schneider EcoStruxure platform, covering 19 ATU instances across multiple iterations, with on-site commissioning support included.

DelaControl replaced an end-of-life Toshiba PLC controlling an industrial electric oven with a modern Siemens S7-series controller, including a full software rewrite and on-site commissioning support.

DelaControl delivered a complete control system for a three-skid gas compression installation, covering electrical design, panel build, FLEX I/O junction boxes, PLC and HMI software development, and pre-delivery testing across all three skids. The Allen Bradley ControlLogix platform was used throughout, with WEG variable speed drives, ATEX-rated intrinsic safety barriers for RTD inputs, a UPS-backed 24 V DC supply, and an IoT gateway for remote connectivity.

DelaControl designed and built a large fleet of Schneider-based control cabinets across multiple machine variants for a UK tobacco industry customer. Working to the customer's own electrical design, DelaControl managed procurement, panel build, testing, and documentation for a substantial number of main control, local, and HMI enclosures — all built and factory acceptance tested at DelaControl's Bristol facility before delivery.

DelaControl designed, built, tested and delivered a large fleet of LineVision control cabinets across two UK food manufacturing sites for the same customer. The scope spanned hybrid hub panels, satellite panels, server room interface panels and associated networking hardware — all on a Siemens platform — with each successive site roll-out drawing on the proven architecture established at the first.

DelaControl designed, built and tested two control panels for a specialist glass processing OEM, covering the full scope from hardware procurement and panel build through to a complete redevelopment of the HMI and PLC software. The project delivered a modernised operator interface, restructured and modularised PLC code, and a full documentation pack including a SISTEMA safety assessment.