Case Studies

E Tech Group has been an industry-leading automator and systems integrator for thirty years. In that time, we’ve accumulated our fair share of success stories. Explore them below.

Dive Into Our Pool of Life Sciences Expertise

End-of-Life Control System Upgrade

A large biotech company knew their legacy control systems were approaching end-of-life, making an upgrade essential for their site in California. E Tech Group provided several control system upgrades to their systems that accommodate present capacity and future growth.

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New Control System for a Pharmaceutical Manufacturer

E Tech Group’s control system engineers implemented a low-cost Rockwell Automation PlantPAx process automation system to upgrade a single-product semiwork facility. The new control system improved quality, consistency and speed of manufacturing by automating previously manual processes.

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Biotech Expansion to Full-Scale Manufacturing

A promising biotech startup with drug candidates progressing from stage 2 to stage 3 clinical had limited automation staffing. The startup turned to E Tech Group to transition their processes to full-scale manufacturing with a fully-integrated system.

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Customized Validated Critical Monitoring System

A growing biopharma company building a new pharmaceutical research lab at their New England facility had an extremely condensed timeline. They reached out to E Tech Group to provide the qualified automated monitoring and alarm system (QMAS).

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Rockwell Control System for Pharmaceutical Manufacturer

E Tech Group’s engineers implemented a low-cost Rockwell Automation PlantPAx process automation system to upgrade a single-product semiwork facility. By automating manual processes, the new control system improved quality, flexibility and consistency with reduced paper-based documentation.

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Implementation of an FDA-Compliant Process Control System

A monoclonal antibody production facility needed a custom, fully-integrated automation system. E Tech Group’s process control solutions included a manufacturing execution system for FDA-compliant data collection and reporting, and a building management system with fully-integrated automation controls.

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Consultation on Potential Control System Upgrade

A long-term biotech client asked E Tech Group to consult on the analysis of their current control system and evaluate potential new platforms. The extensive automation system upgrade and conversion to a new platform provided the client with the capacity for long-term growth.

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Biotech Manufacturing Scale-up with Rockwell & OSI Historian

A biotech startup required a comprehensive automation system to transition to manufacturing. E Tech Group designed, installed, configured, and tested a new OSI PI Historian system compliant with FDA’s 21 CFR Part 11 regulation and EU GMP Annex 11 on electronic signatures and records.

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Biopharma Hybrid SCADA Solution with PlantPAx

E Tech Group developed a hybrid SCADA solution for a BMS in a biopharma co-packing facility utilizing two different controllers and operating systems that would operate in unison. The new automation system allowed the facility to ramp to full operation at once, and to incrementally upgrade as needed. 

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Custom QBMS Upgrade Enhances Existing Functionality

A pharma client was operating on an aging, unsupported QBMS automation system. E Tech Group developed and integrated a creative control system solution delivering the desired functionality between previously incompatible software and hardware components.

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Explore Our Missions in Manufacturing

Automation Helps Food Manufacturer Ramp Up Production

A food production client required a fast-track automation project for a 110,000-square-foot addition to an existing food processing facility. Our engineers used Rockwell Automation technology to program process automation controllers, troubleshoot, and upgrade support for a manufacturing expansion.

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Increased Throughput Capacity at a Global Parcel Hub

An international parcel service was asked to increase throughput at an older hub in order to meet peak-season demand. Our engineers upgraded 70% of the site’s control systems and expanded the control room and package handling systems for a turnkey automation solution.

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Large-Scale Electrical & Mechanical Safety Controls Upgrade

A global battery supplier was dealing with machinery that couldn’t keep up with updated industry safety standards. They reached out to E Tech Group with their initiative to bring 99 machines into compliance with the most recent electrical and mechanical safety guidelines.

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Zero-Downtime Control System Revamp Avoids Obsolescence

A pickle producer facing end-of-life issues with their automation system required an extensive upgrade to their facility’s control systems without interrupting production. E Tech Group’s close collaboration with the client helped accomplish the transition smoothly.

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Obsolescence Forces Large-Scale Assessment & Remediation

A previous E Tech Group employee who now works for a large material handling company recognized there was potential large scale obsolescence in control systems across 36 facilities. They reached out to have our team assess and provide plans for remediation and optimization.  

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Manufacturing Automation Examples: Robotic & Palletizing

Check out these videos of robotic and palletizing automation solutions that E Tech Group has designed for clients. Includes palletizing, dual palletizing, AGV solutions, infeed singulators, sortation conveyors, and more. 

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Turnkey Factory Automation for Alternative Protein Pilot Plant

An alternative meat producer needed to prove it was possible to replicate their lab results in an increased volume setting for large-scale production and distribution. E Tech Group designed, built and implemented a custom control system on Rockwell’s PlantPAx automation platform.

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Robotic Automation for Improved Output & Workplace Safety

E Tech Group was able to automate a once completely manual process for a food manufacturing facility that was struggling with employee retention and meeting output demand due to physically demanding and environmental factors on the floor. 

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Updated Label Detection System for Bottling Facility

Quality assurance issues were plaguing a bottling facility as their current label detection system wasn’t catching missing or misapplied labels.  E Tech Group was able to integrate three control systems into one, resulting in more accurate detection and less defects. 

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SCADA & PLC Control System Upgrade on a Tight Timeline

A rice milling company needed a new PLC in a truncated timeline. E Tech Group’s project team inventoried equipment and upgraded the facility to Ignition SCADA software, setting the client up to meet short-term goals and be prepared for long-term growth.

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PLC-5 to ControlLogix Controls Platform Migration

A global supplier of spice ingredients needed to upgrade their Allen Bradley PLC-5 system. E Tech Group modernized their obsolete PLC system to a more IIOT friendly platform that improved performance, greater uptime, and a more user-friendly interface for the client’s PLC system.

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Spicing Up Success: A Flavorful Transformation in Spice Production by Leveraging Rockwell Automation Solutions

A supplier of culinary spices needed to upgrade from manual control to automation, this success story highlights how Rockwell Automation solutions supported increased throughput and cost reductions.

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Ignition Platform Provides Organization-wide Access to Quality Data for Cherry Packaging Company

E Tech Group helped Prima Frutta increase productivity by 50% without hiring extra personnel by using the Ignition platform, which allowed remote operation of the production line and real-time data access from any smart device.

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Designing a Flexible and Scalable Automated Processing System for The Better Meat Co.

The Better Meat Co. collaborated with E Tech Group and Barnum Mechanical Inc. to design, build, and automate a full-scale processing system that has been successful in producing on-demand production and is scalable for future growth.

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Discover E Tech Group’s Experience in Metals

Remote SCADA Maintenance & Troubleshooting

A steel manufacturing company was experiencing errors and downtime with their SCADA system. E Tech Group’s engineers swiftly identified and eliminated the error remotely, getting production back online in less than a half hour and saving the client cost of on-the-floor support.

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Control System Integration for an Industry-Leading Steel Mill

E Tech Group was hired for a large project by a leading steel company to increase throughput and safety on the customer’s six stand cold mill line. Improvements to the cold mill yielded measurable financial savings by reducing defects and improving the safety of their automated processes.

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Emergency Support Call & Steel Mill Line Controls Upgrade

After a steel mill client experienced a flooded basement and damaged equipment, E Tech Group upgraded the obsolete drives, PLC, HMI, and automatic tension control mode. The result was reduced head and tail off gage, inner stand strip breaks, and electrical downtime.

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Aluminum Exit Line Automation & Control System Upgrade

An American industrial company specializing in aluminum products contacted E Tech Group to upgrade and integrate their exit line automation and controls, which were previously running on vintage reliance analog drives from the ‘60s.

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Roll Coater Paint Line Update for Steel Company

A leading steel manufacturer needed to add lite gage steel to their roll coater pain line’s capabilities. Our engineers expanded line capabilities and upgraded to state-of-the-art Siemens digital drive systems to improve line speed, reduce downtime, and a return to original OEM spec speed.

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1.5 Year ROI on a $2M Line Automation Recontrol

A steel service center was experiencing a troubling trend in increasing downtime and scrap losses. E Tech Group proposed modernized controls and programmable drives. A complete control system rebuild resulted in dramatic line improvements and a 12-18 month projected ROI.

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Cybersecurity IT/OT Assessment & Remediation

After being the target of numerous ransomware attacks, a metals manufacturer called on E Tech Group to perform an IT/OT assessment to assess and remediate vulnerabilities. A cross-functional team strategically performed a risk and vulnerability assessment and created a plan to update their facility. 

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Pig Castor Project Pours Hot Metal Ahead of Schedule

E Tech Group’s role shifted to a Main Automation Partner for a metals project with an ever-evolving scope of work. Our team effectively managed risks and delays, communicated changes promptly, and maintained a strict timeline, which ultimately enabled the client to complete the metal pouring process ahead of schedule.

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Peruse Our Successes in Material Handling


Lift Table Motor Burnout Remedied by Signal Delay Timer

A customer had been experiencing motor failures on hydraulic lift tables in their distribution centers and couldn’t figure out why. E Tech Group automation engineers diagnosed the problem and creatively fixed the issue with a signal delay timer.

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IT/OT Network Assessment to Avoid Obsolescence

A material handling company wanted their network integrated and optimized. Our automation engineers documented and assessed the client’s IT/OT Infrastructure to help identify critical components near obsolescence or end of life.

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Digital Twin Provides Insight into Manufacturing Processes

Digital Twin technology allows for an interconnected system that provides its users with immediate data, a user-friendly production display, easy diagnostics, remote support, and troubleshooting. 3D models of automated manufacturing lines provide operators with a tool that supplies insight on their processes.

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Upgrading a Food Production and Distribution Center’s Conveyor System Increases Efficiency, and Safety 

A food production and distribution facility contacted E Tech Group to assess and upgrade the conveyor increasing output, efficiency, and safety.

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Taking over a system upgrade to get a client back on track and operational

A fulfillment center needed to upgrade its obsolete system which was no longer operational. E Tech Group traveled on-site and overcame a multitude of challenges to get the client operational in their allotted timeframe.

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Distribution Center PLC Fault Detection Techniques Streamline Parcel Sortation Operations

E Tech Group helped a global parcel services provider with PLC program development, troubleshooting, and system start-up to meet a tight timeline and improve productivity.

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Distribution Center PLC Fault Detection Techniques Streamline Parcel Sortation Operations

E Tech Group helped a global parcel services provider with PLC program development, troubleshooting, and system start-up to meet a tight timeline and improve productivity.

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Updated Server and SCADA Environment with 24/7 support remedies global courier’s delays

A global courier was facing delays and fines caused by an aging system.  E Tech Group determined a complete overhaul of the operational infrastructure and the addition of on-call support was necessary to remedy the issue.

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US-Based Upgrade and Support Success Prompted International Scale-Up for Global Courier Leader

The overwhelming success of infrastructure upgrades and added support in US-based sites paved the way for an international scale-up as multiple European sites were optimized.

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Plug Into E Tech Group’s Advancements in Mission Critical


Water Treatment Plant Control System Upgrade

An irrigation water district treatment plant’s decades-old control systems were nearing end of life. E Tech Group automation engineers upgraded the primitive control system to allow for remote monitoring and control of some of their systems, more reliability, and less maintenance.

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Parallel Integration of Electrical Power Monitor System & Existing System

E Tech Group installed and commissioned a standard Electrical Power Monitoring System (EPMS) in parallel with an existing system to maintain the original combined EPMS and Building Management System (BMS) until it could be upgraded.

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Mitigating Risks Through Modernization: PLC/HMI and Radio Upgrade Plus Water Well Expansion

Outdated systems can become liabilities if not replaced or upgraded with modern solutions. E Tech Group successfully advised and implemented an advanced system for one of their environmental management clients.

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