In the industrial sector, there are certain subfields that require more rigorous automation solutions than others. For instance, continuous manufacturing, where any downtime, unexpected or not, is an urgent situation with significant implications. A step further is the mission critical field – wastewater facilities, power plants, data centers, and hospitals.

Where downtime is a huge risk for continuous manufacturing facilities, it is absolutely devastating for mission critical facilities. Consider the incident in 2010 where the automation system at a wastewater facility in Toledo, Ohio failed and millions of gallons of untreated wastewater was released into the city’s water supply. It left nearly half a million people without safe, potable water for over a week.

Just like the Ohio wastewater crisis, these consequences can be far-reaching, societally, which is why automation for mission critical entities like data centers must be flawless. They need to be robust, redundant, secure, and user-friendly. They can’t have blind spots. They need analytics that predict imminent issues and perform predictive maintenance.

Let’s look at why mission critical automation is different:

Understanding Automation for Water Utilities

There are factors wastewater facilities deal with that aren’t common in many other sectors of industrial automation. Nor can we forget the immediate and potentially-dire risks that come with them. For instance, automated processes in water utilities deal with:

• Biohazard waste and treatment chemicals
• Massive volumes of continuous data
• 24/7/365 operation
• Strict regulations

This requires that automation systems for wastewater facilities:

• Perform real-time data analytics
• Have comprehensive, multi-level network security
• Be reliable and consistent to keep with regulations
• Be easy for users to interact with and configure

What’s different about water utilities, as opposed even to most other mission critical facilities, is that the risk of automation system failure poses immediate, widespread, physical risk to the public. Robust, fortress-like control systems are unquestionably essential to this field of industrial automation.

Data Center Automation is Unique

Data centers are a newer sector, but they’ve quickly become something our society relies on to function. This trend will not slow down. Automation for data centers doesn’t have time to learn and catch up; it needs to meet all criteria, now. Data center automation differs from other sectors of industry because:

1. Data centers are critical infrastructure that must be operational at all times. This means that the automation systems must be highly reliable and resilient.
2. Data centers often contain sensitive data that must be protected from unauthorized access. This means that the automation systems must be secure.
3. Data centers are often complex environments with a large number of interconnected systems. This means that the automation systems must be able to manage these systems effectively.

While the consequences of system failure aren’t physical as they are with wastewater, that does not mean they’re not consequential. System failures can put thousands of people’s personal data at risk, cause significant financial losses, lead to regulatory fines, etc. Multilevel security that provides total coverage for every system in the facility is a non-negotiable in data center automation.

How Mission Critical Automation Provides Solutions

As the needs for mission critical entities are myriad and specialized, there are obstacles to overcome. Automation systems for data centers and water utilities are complex, with many interconnected processes that need to communicate clearly and consistently. They need unmatched cybersecurity. They need to be flexible without compromising reliability, to always stay above regulatory benchmarks.

When it comes to something as sensitive as a data center or wastewater facility, human error can also be a security vulnerability. Automation systems for mission critical can eliminate human shortcomings in crucial processes like:

• Infrastructure provisioning and configuration
• Application deployment and management
• Security monitoring and response
• Performance monitoring and optimization
• Disaster recovery and business continuity

Implementing a turnkey automation system for a mission critical entity like data centers, water utilities, power plants, etc, results in tangible benefits for the company’s operations and reputation:

• Improved efficiency: Automation eliminates human-borne efficiency issues like error and inconsistency, minimizing manual tasks and streamlining processes.
• Improved security: Automation systems are built with robust security features that provide real-time visibility into security threats.
• Increased reliability: Automation tech helps organizations to improve the reliability of their systems and processes by improved consistency, tracking, configuration, etc. This prevents security breaches and critical system failures that cause downtime.
• Reduced costs: Automation reduces costs by eliminating manual labor, reducing errors, and improving the efficiency of their operations.

Automated systems for mission critical that are tailored to the sector and the specific facility are the way to reap the potential benefits of switching to or expanding automated systems in data centers and wastewater facilities. Control system integrators can design, build, stand up, and provide ongoing support for facility-wide automation systems. This keeps these facilities operating at their best, drastically cutting risks associated with security and system failure.

The key is choosing the right industrial automation company to partner with.

E Tech Group: Custom Automation Services for Data Centers & Wastewater Facilities

E Tech Group is a leading North American control system integrator providing unmatched automation services for mission critical facilities, including data centers and water utilities. We have deep domain expertise in this sector of industrial automation, which has provided us with an intimate understanding of the multitude of rigorous requirements endemic to mission critical automation. With clear communication and close collaboration, we help data center and wastewater clients ensure secure, reliable, compliant operations are a 24/7/365 reality.

Industrial automation is a wide-ranging and ever-evolving field. Change is endemic when it comes to automation technology, just as change is endemic to the industrial sector. Whether it’s pharmaceuticals, data centers, wastewater or cultivated meat, the robotic processes and their control systems must meet or exceed compliance standards, which are also a moving target.

The dynamic nature of automated plants makes finding the right control system integrator vital to growth-oriented companies. The right integrator can ensure your endeavors are supported by a comprehensive automation system that provides security, consistency and scalability.

In the automation industry, CSIA-certified automation companies stand out amongst the crowd, making them the best choice of system integrators for companies focused on the future of their industry. E Tech Group is one of those certified automation firms. What exactly does that mean? Let’s discuss:

What Does CSIA Certification Entail?

The Control System Integrators Association (CSIA) is a non-profit organization that sets standards for the automation industry. Dedicated to the advancement of the automation industry, CSIA supports its members in improving their skills and standards, as well as provides a global forum for sharing industry expertise. Their vision is to provide low-risk, safe, and successful automated systems across all industries.

Founded in 1994, the CSIA now has 500 members in 35 countries. To become a member of the CSIA, a control system integrator must meet the following criteria:

• The applicant is engaged in control system integration primarily for design, programming, and commissioning.
• Applicant must provide integration services primarily with its own personnel.
• Applicant may be asked to provide financial data to the CSIA CEO and be interviewed by phone by CSIA members to verify that the applicant meets membership eligibility requirements.
• Applicant agrees to comply with CSIA bylaws, rules and regulations.

Source: Official CSIA website

But being a member is just the first step. The CSIA recommends that within 3 years of becoming a member, companies should achieve their integrator certification, which entails a comprehensive audit of all aspects of an automation company’s operations – from general management to HR, system development, quality management, and more.

For the system integrator to achieve CSIA certification, they must meet or surpass all the CSIA’s best practices at yearly audits. E Tech Group has been a certified member of the CSIA since 2000, leading the industry in our commitment to supporting manufacturer growth with robust, adaptable and scalable automation systems.

What Benefits Does Contracting a CSIA-Certified Integrator Offer?

CSIA-certified automation companies are growth-oriented, which means their eye is always on the future: the future of automation tech, the future of industrial manufacturing, and the future of their clients. Achieving and retaining certified status means a system integrator is invested in the quality of their services, systems and products.

CSIA integrators must be proficient in:

• End-to-end project management
• Effective risk assessment and mitigation
• Awareness and ability to comply with industry and company standards/regulations
• Knowledge and experience in implementing the latest automation technology

What advantages does this offer a company looking to install or upgrade control systems? Namely:

• CSIA certification is a mark of quality: Choosing to become a certified integrator means the company is committed to providing the best in control system design and implementation.
• Certified integrators are committed to improvement: Achieving and retaining a CSIA certification requires the integrator to continuously grow their skill set by adhering to or exceeding best practices and keeping up on the latest in automation technology.
• CSIA certifications mean the company has a network: The CSIA is comprised of a cooperative network of automation integrators and vendors. A certified integrator has access to and partnerships with other top-tier companies with automation expertise.

These characteristics of a certified system integrator mean a client can expect peace of mind, knowing their project will be done by the best in the business with the latest technology and a wealth of experience behind each of their projects. On a tangible level, cutting-edge automation systems offer returns in:

• Increased security
• Increased throughput
• Increased quality consistency
• Sustained scalability
• Decreased risk
• Decreased defects
• Decreased incidents
• Decreased downtime

E Tech Group’s Capabilities as a Certified System Integrator

E Tech Group is a CSIA-certified control system integrator providing the best in automation design and end-to-end project coverage to clients across industries. Some of the industries we serve include:

• Life sciences, including pharma, biologics, biotech, and medical devices
• Mission critical, including data centers and water utilities
• Food and beverage, including the emerging cultivated meat/alternative protein sector
• Manufacturing, including CP, chemical, metals, automotive, OEM, and marine
• Material handling, including distribution centers and parcel hubs

And E Tech Group has many capabilities to offer these industries in their automated processes. Hundreds of E Tech Group automation engineers provide clients across North America with a comprehensive understanding of:

• Continuous and Batch Processing
  • Process Automation
  • Control System Integration
  • S88 Batch Control Systems
  • Panel Design & Custom Fabrication
  • Specialty Drive Systems
• Discrete Manufacturing
  • Motion Control
  • Machine Automation
  • Robotic Automation
• Operations and Management
  • Building Automation
  • Safety Systems
• Cybersecurity and Industrial IT
  • Industrial IT
  • IT/OT Risk Assessments & Analysis
  • Advanced Software Applications

Work With E Tech Group, a CSIA-Certified Integrator, for Your Automation Needs

E Tech Group is a certified control system integrator offering industrial clients the best in automation design. Clients can expect robust, cutting-edge control systems that lower risks, increase safety, optimize production specs, and exceed compliance benchmarks.

As a certified control system integrator, we also partner with the top vendors in automation software, including Rockwell Automation, Emerson, Siemens, Ignition, and more. A collaborative and creative approach to each project, coupled with diverse expertise in implementing custom automation systems, ensures every client is set up for future success with a scalable, turnkey control system.

It’s no secret that automation and robotics are the future of industrial manufacturing. The advent of AI and machine learning has only sped up this process, allowing manufacturers to better manage everything about their production while lessening the need for human labor in repetitive tasks.

But unless you’re a start-up with a brand-new facility, you’re likely dealing with a piecemealed automation system that isn’t allowing your production line to perform at its best. Outdated control system infrastructure poses risks to facility security and safety, production throughput, compliance, consistency, and more.

It’s a reality that industrial producers need to contract automation engineering firms to help them catch up to the head of the curve. But that takes a control system integrator that understands the nuances of this new, ever-evolving field of automation, and designs their integrated systems with an eye towards the future of industrial automation.

Facility-Wide Automation Systems Are Here to Stay

Before we discuss the importance and hallmarks of automation system integrators in the industrial sector, let’s take a quick look at why these companies are key partners to companies of all shapes and sizes:

• In 2022, the global market for building automation systems was 81.3 billion. This grew to 90.3 billion in 2023.
• Approximately 1/3 of this market is North America alone. North America is projected to remain the leading region in factory automation expansion.
• The building automation system market is projected to be worth 143.1 billion by 2027.
• Turnkey automation can drastically reduce the 30% energy loss typical of industrial commercial facilities.

Throughout all this growth and proliferation, E Tech Group automation partners Rockwell Automation, Siemens AG and Schneider Electric SE are three of the top automation vendors worldwide.

The Place of Factory Automation Companies in Industrial Production

Just like manufacturers are trying to find what’s best for them when it comes to improving their facility automation, so, too, are building automation companies looking for ways to facilitate those new and evolving needs. Engineering companies are constantly learning new software and adapting their approach to control system design in real-time.

Industrial automation companies whose engineers keep apprised of new tech and how to best implement automated processes can offer industrial manufacturers tangible results, such as:

• Additional line capabilities
• Better IT/OT security
• Improved safety and compliance
• Increased flexibility
• Increased production capacity
• Labor shortage resilience
• Less system malfunctions and downtime
• Scalability

Consider the impact of these advantages. Increased testing throughput in a pharmaceutical facility means faster speed to market. Validated processes allow food and beverage producers to improve quality and consistency. Zero Defect control system design drastically cuts malfunctions and downtime in water utilities plants. Live data analytics reduce strip breakage and defects in metals production. These things set each company, and their industry at-large, up for sustainable, long-term growth and improvement.

Turnkey Factory Automation Requires a Strategic Approach

Past understanding how to use and implement the right automation and control system technology is how to build a robust plant-wide system infrastructure by piecing together the best automation products for a specific industrial enterprise. That means using the right hardware and software, as well as understanding obstacles and how to overcome them.

The Equipment

The hardware an integrator uses can either hinder or help facilitate the automation system and its usability. A building-wide control system infrastructure must integrate numerous systems, including:

• Actuators
• HMIs
• Motion control systems
• PLCs
• Robotics/Cobots
• Sensors

E Tech Group manufactures custom control panels and associated hardware so that these physical pieces can easily assimilate with the software that supports them.

The Tech

Automation software is just as important, if not more. If you have an existing facility that needs a control system upgrade, this is where E Tech Group can help update and improve automated equipment that is outdated but too costly to replace. We utilize automation products from the most innovative brands like:

• Rockwell Automation
• Siemens
• AVEVA
• Allen-Bradley
• Ignition
• Schneider
• Emerson

And our building automation strategy stays ahead of the technology curve by incorporating things like:

• Data historians
• Digital twins
• DSCs
• MESs
• Big data analytics
• Robust reporting systems

With every client, the goal is to build or upgrade a control system that will be easy for them to use and augment as their facility continues to change and grow. Our approach to facility-wide automation focuses heavily on cybersecurity and comprehensive yet elegant integration. We manage system builds and upgrades from start to finish so you can reap the rewards of this top-tier tech and equipment immediately upon implementation.

The Challenges

Another vital facet to each project is the obstacles we have to overcome in order to get the client exactly what they need for now and for the future. Often, the biggest challenge we face is integrating people with technology. Common and natural barriers we are adept at resolving include:

Fear of Change

With any plant-wide automation upgrade, there is naturally reticence on the part of operations. It’s justified – they are the ones who’ll be using the system, and they’re the ones whom the system infrastructure will affect day in and day out. But resistance to change is often more fear of the unknown than anything.

From shop floor to the top floor, E Tech Group integrates seamlessly. We work closely with on-the-floor staff from the outset of a project, taking into account operations’ needs, wants and goals. A collaborative approach makes everyone feel important and included in the process, which can greatly alleviate negative emotions around the system upgrade as well as help streamline transition to the new system.

Education and Training

Including all impacted parties throughout the course of the control system build also helps educate everyone on the system as it’s being designed, which sets the client up for a smoother transition upon implementation. When users understand how all the parts of the control system work together, they will naturally be able to better manage the system.

E Tech Group also provides thorough training programs for each project, using experiences along the way to educate us on what the most important features will be to the users and what style of training will work best for your staff. A well-trained staff makes for a smoother transition and less downtime.

Budget constraints

More often than not, the budget is the biggest hurdle a client faces when considering a complete factory automation build or upgrade, and E Tech Group’s track record of on-budget projects that exceeded client expectations is unmatched. Our organic and collective approach to project progress, as well as our ability to find modular, compatible automation software that can save equipment previously deemed obsolete, save clients time and money.

Tailored Control System Integration to Future-Proof Your Facility

With over 30 years of experience in the automation industry, E Tech Group is one of the largest engineering, building automation and control system integration companies in the US. Covering all of North America, and with 18 offices spanning coast-to-coast, our automation engineers have deep domain expertise in industries such as:

• Food and Beverage: packaged foods, alternative proteins
• Life Sciences: pharmaceutical, biologics, R&D labs
• Manufacturing: metals, automotive/OEM, chemical, marine, CP
• Material Handling: industrial distribution automation
• Mission Critical: data centers, water utilities

As a company providing clients turnkey factory automation services, E Tech Group’s unique approach to control system design and implementation sets clients up for immediate and long-term success. Key obstacles manufacturers today face are pivoting to automation, and finding automated solutions that are adaptable and scalable.

E Tech Group performs thorough audits and assessments, conferring with your team to design and implement a building-wide automation system that is secure, redundant, intuitive, and precise. As well, our brand of control system integration lets the client retain the ability to:

1. expand their production line’s throughput and quality,
2. incorporate new/different products into the automated system, and
3. scale up the system without the need for complete retrofits at each step.

Our distinct skills in factory automation, collaborative approach to system design, and availability to provide ongoing support after project end, ensures E Tech Group clients are set up for success with a robust control system that supports their current and future goals.

Our distinct skills in factory automation, collaborative approach to system design, and availability to provide ongoing support after project end, ensures E Tech Group clients are set up for success with a robust control system that supports their current and future goals.