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 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, 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 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 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, 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 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 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 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 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 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 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.

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 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.