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CASE STUDY

Controls Upgrade — Pulse Crop Processing Plant

PLC & SCADA Modernization for Dry Pea, Lentil & Chickpea Processing

The Challenge

Pulse crop processing plants — handling dry peas, lentils, and chickpeas — run complex, sequential equipment chains where a failure or mis-operation at any point cascades downstream. The client's Valley location processing plant was operating without centralized automation controls: operators managed the process manually, without real-time status visibility, centralized alarming, or a structured start/stop sequence to protect equipment.

The absence of a modern control system created compounding risks:

• 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 client needed a turnkey controls upgrade that would bring the entire Pellet Mill operation under unified supervisory control — without requiring a full plant rewire or replacement of existing motor control equipment.

The Solution

Logic Control Systems designed and built a complete controls system for the Valley location processing plant — including hardware fabrication, PLC programming (TwinCAT 3), and HMI development (Ignition) — to automate and supervise all connected equipment.

Operator Console

A full height/width operator console was built around a Beckhoff 17" industrial touchscreen display, backed by a thin-client PC running the Ignition HMI. An internally mounted EtherCAT adapter interfaces with 16 digital inputs, 16 digital outputs, 4 analog inputs, and 4 analog outputs — giving operators complete process visibility and control from a single workstation.

MCC Room Control Enclosure

A dedicated enclosure in the MCC room houses the TwinCAT 3 PLC and all field interface hardware:

• 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.

Field Instrumentation & Motor Monitoring

Two Current Transducers (CTs) are installed on the Grinder and Pellet Mill to monitor motor amperage load in real time. Amperage data feeds directly into the HMI, enabling operators to watch machine loading, identify overloads before they trip breakers, and track process performance trends.

Seven existing push-button digital inputs were integrated into the PLC to retain the ability to start fan motors through their original controls — preserving familiar operator muscle memory while adding the motors to the centralized supervisory system.

Software: TwinCAT 3 PLC + Ignition HMI

Logic Control Systems programmed the TwinCAT 3 PLC to automate the full operating sequence of the Pellet Mill's connected equipment, including interlock logic that enforces correct start/stop sequencing to protect motors and mechanical components.

The Ignition HMI — already licensed by the client — was configured by LCS to provide:

• Real-time equipment status displays for all connected devices.
• Grinder and Pellet Mill amperage trending and live readouts.
• Alarm management with operator acknowledgment and alarm history logging.
• Start, stop, and operational control of Pellet Mill equipment including the filtration system.
• HOA mode status visibility — showing whether each device is in Hand, Off, or Auto mode.

The client already owned an active Ignition license. LCS leveraged that existing investment to build a full-featured SCADA/HMI layer at no additional software cost — maximizing value on the controls upgrade.

Commissioning & Startup

Once the client's electrical contractor completed installation and energization of the new enclosures and field wiring, Logic Control Systems returned on-site to commission the system. Commissioning included:

• I/O verification — confirming every digital and analog point mapped correctly between field devices and the PLC.
• Sequence validation — testing full start/stop cycles and confirming interlock logic performed as designed.
• Amperage transducer calibration — verifying CT readings in the HMI matched actual motor loading.
• Alarm testing — triggering fault conditions and confirming operator alerts functioned correctly.
• Operator walkthrough — walking the client's team through HMI navigation, alarm response, and HOA override procedures.

Technology at a Glance

Results & Impact

The completed system transformed the client's Valley location processing plant from a manually managed process into a centrally supervised, automated operation:

• 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 is a Texas-based industrial automation integrator specializing in PLC programming, SCADA/HMI development, process control, electrical panel fabrication, and remote automation maintenance. We serve manufacturing clients across the U.S. in industries including pulse crop processing, food processing, chemical, oil and gas, pharmaceutical, and water/wastewater — most often modernizing legacy systems to extend equipment life and improve operational efficiency.

UL Certified • Ignition Certified Integrator • ISNetworld Member • Fortinet Partner