Every project below is a real installation — real savings, real uptime improvements, real clients.
A Morbi tile manufacturer was running 12 ball mills on fixed-speed direct-on-line starters. Power consumption was high and ball charge wear was excessive due to constant full-speed operation. We installed Siemens SINAMICS G120 VFDs on all 12 mills with a PLC-based batch timer and speed ramp control. Each mill now runs at optimised speed for its batch stage.
A Rajkot foundry was operating its 2-tonne induction furnace manually — relying on operator experience for temperature control. This caused metallurgical inconsistencies and high scrap rates. We implemented a Siemens S7-1200 PLC with thermocouple inputs and a Delta HMI for temperature monitoring, melt profile selection, and tapping alarm. The operator now monitors the entire process from a single touchscreen.
A Gujarat municipality needed remote visibility and control of 4 booster pump stations spread across 12 km. We installed Omron CJ2M PLCs at each station with GSM-based SCADA communication to a central control room. Operators can now start/stop pumps, monitor pressures, and receive SMS alerts on their phones for any fault.
An existing spray dryer was controlled by pneumatic timers — unreliable and energy-wasteful. We replaced the entire combustion control system with a Delta DVP PLC, thermocouple inputs, gas valve actuators, and blower VFDs. Outlet temperature is now maintained within ±2°C of setpoint — improving powder moisture consistency and reducing gas consumption.
Designed and manufactured a 24-feeder MCC panel for a new ceramic tile factory in Morbi GIDC. Panel includes DOL and star-delta starters for 24 motors up to 75kW, with IS/IEC 61439-compliant construction, Form 3b segregation, and IP54 enclosure suitable for dusty ceramic environments.
Managing AMC for 3 ceramic tile factories in Morbi covering 80+ drive units, 12 PLC controllers, and 25 MCC panels. Quarterly preventive maintenance visits, priority breakdown response, and spares holding programme. Average unplanned downtime reduced from 18 hours/month to under 3 hours/month across all three plants.
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