Client Challenge
A leading provider in the recycling industry required a comprehensive automation solution for a new materials recovery facility (MRF) in the Northeast. The facility needed a robust control system capable of managing complex recycling processes, ensuring safety, and meeting stringent environmental standards.
It was essential that the new automation solution be not only technically sound but also energy-conscious, with systems that would support responsible resource usage over time. Our client needed a trusted integration partner who could manage both the technical demands and sustainability priorities from end to end. The scope of work called for a complete control system design, UL-certified panel fabrication, PLC and HMI programming, industrial network architecture, and on-site supervision of the electrical installation.
Our Solution
- UL Panel Design & Integration: DSI Innovations designed, fabricated, and delivered UL-labeled MCC panels and remote I/O enclosures equipped with advanced Siemens S7 safety PLCs and a WinCC SCADA system.
- Reliable Communication Infrastructure: A detailed industrial network design was developed to ensure dependable communication across critical plant areas. The Profinet-based architecture was built for speed, resilience, and expandability.
- Optimized System Control: Comprehensive PLC logic and HMI programming services were provided, enabling operators to monitor and control equipment in real time. Custom graphical interfaces were created to streamline daily workflows.
- Energy & Safety Efficiency: Environmental priorities were addressed by integrating LED lighting for energy savings, extensive emergency lighting for safe evacuation, and smart motor controls to reduce energy waste and promote operational longevity.
- Testing & Certification: DSI managed a complete Factory Acceptance Test (FAT) process, supervised the I/O checkout on-site, and ensured full installation compliance. Onsite training was delivered to empower staff with the knowledge to operate and maintain the new system effectively.
The Results
- Increased Efficiency: The fully integrated control system enabled efficient startup and reliable operation of the recycling facility, streamlining workflows and reducing manual intervention.
- Enhanced Uptime & Visibility: The addition of centralized monitoring and robust safety systems led to reduced downtime and improved response times to equipment alerts.
- Sustainable Impact: Energy-efficient lighting and smarter motor strategies helped the facility align with broader sustainability goals, reducing overall energy consumption and environmental footprint.
- Future-Ready Systems: With scalable architecture and built-in diagnostics, DSI Innovations delivered a long-term automation solution that supports the client’s commitment to environmental responsibility and operational excellence.
