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CASE STUDY

Controls Upgrade — Pulse Crop Processing

TwinCAT 3 PLC & Ignition SCADA System for Spokane Seed's Pellet Mill

The Challenge

Spokane Seed's Pellet Mill lacked centralized equipment monitoring, alarm management, and interlock logic — creating operational risk and limiting visibility across the processing line.

• No centralized monitoring of running equipment status or amperage loads.
• No alarm management system to alert operators to faults or abnormal conditions.
• No structured interlock logic to prevent equipment damage from out-of-sequence starts.
• Fan motors started independently from existing push buttons, with no integration into the broader system.

The Solution

Logic Control Systems designed and built a complete controls system for the Pellet Mill, centered on a TwinCAT 3 PLC and Ignition SCADA/HMI platform — delivering full equipment monitoring, interlock logic, and real-time amperage visibility.

MCC Panel

The Motor Control Center panel was built to house the full I/O infrastructure for the Pellet Mill:

• 32 single-pole relay interface digital inputs and 32 double-pole relay interface digital outputs — all using relay interfaces for electrical isolation and field device protection.
• 4 analog inputs and 4 analog outputs for process signal monitoring and control.
• 32 HOA (Hand-Off-Auto) switches — one per relay output — allowing operators and maintenance personnel to manually control individual devices independently of the PLC when needed.
• Two independent E-stop circuits for personnel safety.
• Ethernet switch and power supplies.

Amperage Monitoring

Twelve current transducers were installed on the Grinder and Pellet Mill motors, providing real-time amperage readings to the PLC. This enables early detection of overloads before breaker trips or equipment damage occur.

Interlock Logic

Structured PLC interlock logic prevents out-of-sequence equipment starts that could damage motors or mechanical components — a critical protection for high-value processing equipment.

Fan Motor Integration

Existing fan motors were integrated into the supervisory system, retaining familiar push-button operation while adding centralized status monitoring through the Ignition HMI.

Ignition HMI

The Ignition SCADA/HMI platform provides operators with a single workstation view of equipment status, motor loading, and active alarms across the entire Pellet Mill — building on the client's existing Ignition software investment.

Real-time amperage monitoring on the Grinder and Pellet Mill provides early warning of overloads — enabling proactive response before breaker trips or equipment damage.

Technology at a Glance

Results & Impact

The new controls system gave Spokane Seed full visibility and structured automation across the Pellet Mill:

• Operators now have a single workstation with full visibility into equipment status, motor loading, and active alarms across the entire Pellet Mill.
• Structured PLC interlock logic prevents out-of-sequence starts that could damage motors or mechanical components.
• Real-time amperage monitoring on the Grinder and Pellet Mill provides early warning of overloads — enabling proactive response before breaker trips or equipment damage.
• The HOA switch panel gives maintenance personnel direct, per-device manual control without bypassing safety circuits.
• Two E-stop circuits provide layered personnel safety at the MCC level.
• The Ignition HMI builds on the client's existing software investment — adding full SCADA capability without additional licensing cost.
• Fan motor integration into the supervisory system retains familiar push-button operation while adding centralized status monitoring.

About Logic Control Systems

Logic Control Systems (LCS) is a Texas-based industrial automation integrator specializing in PLC programming, SCADA/HMI development, process control, electrical panel fabrication, commissioning, and remote automation maintenance. LCS serves clients across the U.S. in industries including food processing, fabrication, chemical, oil and gas, pharmaceutical, and water/wastewater.

UL Certified | Ignition Certified | ISNetworld Member | Fortinet Partner