When a major food manufacturer needed an automation system integrator to design and fabricate six UL 508A custom control panels for their new production line, E Tech Group rose to the challenge, and in record time.

The Project: Fabricate Six Custom Control Panels on a Tight Timeline

A major food manufacturer needed a trusted control system integrator to design and fabricate six control panels for their new production line. They chose E Tech Group because of our expertise in building UL 508A control panels, including custom panel design, as well as our ability to source hard-to-find parts, and ability to create alternative solutions to meet tight project deadlines without compromising system quality.

The client required swift project execution and a customized automation solution that included 6 UL 508A control panels. E Tech Group was able to streamline the panel build process by leveraging E Tech Group’s proven project management methodology. E Tech Group rose to the challenge, constructing six UL508A control panels with speed, quality, and engineering integrity to support the customer’s new production line.

The Solution: Collaborate Closely with the Client from Start to Finish

A main challenge was to ensure the project remained on schedule due to long lead items to PLC components, such as safety PLC modules, VFDs, and other components necessary for this integrated control system solution. Our automation engineering team leveraged our efficient panel build process and AG5 project methodology to create a viable solution for the customer across five key phases:

Phase 1 – Collaborate, Plan & Prepare

Following a technical Q&A with the customer and creating a bill of materials, E Tech Group’s project manager collaborated internally with their purchasing department to review project materials and potential long lead items. Long lead items were ordered to ensure the project timeline was not impacted.  

Step 2 – Design the Panels & Source the Parts

Next, E Tech Group’s engineering team created the control panel design, defining the system requirements, developing a device and I/O list, and creating the panel schematics. Every detail had to be considered and carefully planned to support proper functionality when the control panels were later assembled.

Our engineers and drafting team approved the control panel design with engineering leadership as part of our own internal quality control procedures before the panel design was submitted for client approval. E Tech Group’s purchasing department then ordered all automation hardware to support the multiple control panel builds.

When supply chain issues were identified, we quickly informed the project team of unavailable materials to discuss possible alternatives with the client. E Tech Group’s project manager and engineering team worked closely with the client to create a viable food and beverage automation solution with compatible alternatives. The team then regrouped internally to source those alternative hardware options with the purchasing department.

E Tech Group understands that the collaboration and design stages are key to the success of the next phase of a project – building the control panels. Attention to detail and quality control measures lead to faster and higher-quality project outcomes, which is why the first two phases act as a foundation to deploying a well-executed control system solution. 

Phase 3 – Fabricating the UL 508A Control Panels

Once the schematics were completed and the components were received, E Tech Group began building the control panels at their large-scale panel shop in Modesto, California. The panel shop team assembled the six control panels to the customer’s specifications and to comply with UL 508A standards. The panels integrated CompactLogix 5380 Controllers with POINT I/O Safety I/O Modules, PowerFlex 525 AC drives, and Panel View Graphic Terminals for visualization.

Phase 4 – Testing the Assembled Control Panels

E Tech Group’s control panel shop team carefully evaluated each aspect of the assembly process to ensure it complied with safety requirements and functions as intended. The panel shop team performed several evaluations, including point-to-point testing, and produced documentation for the client of how the control panels were built in collaboration with E Tech Group’s drafting team.   

Phase 5 – Deploying the Panels to the Client

With the control panels thoroughly tested and validated for complete functionality, E Tech Group prepared and shipped the control panels to the client’s site for installation.

The Results: An Advanced Automation Solution Delivered Ahead of Schedule

E Tech Group’s multidisciplinary team showcased exceptional results in this project execution, completing the project 4 weeks ahead of schedule. Through seamless collaboration and leveraging diverse expertise, our team achieved high-speed project completion, avoiding supply chain disruptions by sourcing alternative automation hardware without compromising control system or panel quality.

Our control system integration team’s coordinated efforts expedited the timelines, resulting in significant time and cost savings for the client. The emphasis on maintaining high standards throughout the project lifecycle ensured the delivery of quality solutions, ultimately leaving the client highly satisfied with the outcomes achieved for their new production line.