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Electronic Drives and Controls, Inc. (EDC) today announced it is the first U.S. Siemens Solution Partner to be certified for Drives & Motion. A Siemens Solution Partner since 2014, the company is also certified in Advanced Factory Automation.

Electronic Drives and Controls Named First U.S. Siemens Solution Partner Certified for Drives & Motion

Posted on by Georgia Whalen
[vc_row][vc_column width=”2/3″][vc_column_text]Parsippany, NJ – February 28, 2018 – Electronic Drives and Controls, Inc. (EDC), a leading control system integrator and field service company for industrial automation and drive technology, today announced it is the first U.S. Siemens Solution Partner to be certified for Drives & Motion. A Siemens Solution Partner since 2014, the company is also certified in Advanced Factory Automation.

With this new certification, EDC has established itself as a strategic solution partner and leading system integrator focused on helping manufacturers with obsolete drive and control technology to automate manual processes and upgrade aging equipment.

“Our congratulations go to Electronic Drives and Controls. This certification means their clients can always trust that EDC will professionally deliver the most advanced solutions based on the powerful combination of SINAMICS integrated drives and SIMATIC totally integrated automation,” said Peter Treible, National Industrial Partner Manager, Siemens.

“We are proud to have Electronic Drives and Controls as a Siemens Solution Partner! EDC has consistently proven that we can always count on them to deliver quality engineering and implementation services, the first time, every time, for our clients. This investment in certification is one of many reasons Siemens views EDC as a leader in their market.”

EDC has 50 years of experience integrating new control systems and repairing or retrofitting older equipment for a variety of manufacturing industries local to New Jersey, New York and Connecticut. With exceptional domain expertise, the company has also established itself nationwide as the go-to resource for manufacturers in the wire and cable, coating, laminating, and converting industries.[/vc_column_text][/vc_column][vc_column width=”1/3″][vc_single_image image=”921″ img_size=”full” style=”vc_box_shadow_border” onclick=”custom_link” img_link_target=”_blank” link=”https://wp.msn1wyd37fxykd4.static3.studio/wp-content/uploads/2018/02/ELectronic-Drives-and-Controls-Siemens-Solution-Partner-Certification.pdf”][/vc_column][/vc_row][vc_row][vc_column width=”1/3″][vc_single_image image=”883″ img_size=”full” style=”vc_box_shadow_border” onclick=”custom_link” img_link_target=”_blank” link=”https://wp.msn1wyd37fxykd4.static3.studio/wp-content/uploads/2018/02/Electronic-Drives-Controls-Siemens-6SE70-Master-Drives-to-S120-Vector-Drives-1.pdf”][/vc_column][vc_column width=”2/3″][vc_column_text]“For the typical manufacturers we work with, older drives such as Siemens MasterDrives 6SE70 series have been great workhorses for years. We know because we have installed hundreds of them over the years,” said Chuck Dillard, vice president of EDC. “The problem is, as these older industrial drives and controls reach obsolescence, downtime for manufacturers becomes a costly problem with no OEM support and difficulty sourcing replacement parts. We help manufacturers retrofit existing equipment gaining the advantages of new automation technology at a fraction of the cost of purchasing new equipment.”

When upgrading older equipment, automating manual processes allows manufacturers to gain a competitive edge with greater throughput and efficiency. It also sets the stage for leveraging the industrial internet of things (IIoT) and digitalization of the shop floor.

In addition to EDC’s work with the manufacturing sector, the company has a field service business unit. Highly trained technicians perform repairs, large-scale retrofits, and preventative maintenance for customers in the pharmaceuticals, real estate management and HVAC industries.[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]About Electronic Drives and Controls, Inc.
Founded in 1968, Electronic Drives and Controls, Inc. (EDC) is a CSIA Certified control system integrator with a large field service team specializing in AC and DC drives, PLCs and factory automation. Family owned and operated for 50 years, EDC’s team of engineers and technicians has great depth of experience integrating new control systems and breathing life into older equipment. EDC has the engineering capability to design, build, start-up and service projects from the sophisticated to the simple and the service support team on call 24/7/365 to keep it all running at peak efficiency from day 1 and for years to come. In addition to the company’s certification as a Siemens Solution Partner and a Rockwell Automation Recognized System Integrator, EDC is a factory authorized/factory trained service center for over 40 drive brands.[/vc_column_text][/vc_column][/vc_row]

Case Study – From Old to New: Modifying a Legacy Dual Textile Spray Line into an Efficient Machine with Doubled Throughput

Posted on by Georgia Whalen

Heytex, a brand of the German-based Heytex Bramsche GmbH, is a global developer and manufacturer of high-quality technical textiles. Their portfolio includes sophisticated and unique products fabricated and engineered using complex textile technology, such as signage, banners, boats, sales, barriers, and other technical textile products for a variety of customers. Electronic Drives and Controls (EDC), a recognized leader in the design, upgrade, and service support of drive and PLC Systems, recently helped Heytex significantly improve industrial textile coatings equipment for a military customer and double their overall production capabilities. 

Problem

Heytex had previously purchased a used paint line machine at auction that consists of two parallel production lines sharing the same painting booth and oven sections which could run concurrently or separately. However, one of the lines (Line 2) sat idle for approximately three years before Heytex sought help improving its operability to produce spray-painted industrial camouflage textiles for a military customer. Parts from Line 2 were scavenged to keep Line 1 running.

Originally, Heytex would receive an AutoCAD file from their military customer that specified the geometry of the desired pattern to be painted by the machine. Each line has six drives: 3 VFDs for web handling and 3 servo drives to traverse the paint heads. The process begins by feeding industrial fabric through a conveyor from an unpainted fabric roll. Next, three spray heads move across the fabric in a coordinated fashion applying green, brown and black paint resulting in a specified camouflage pattern. The machine then dries the fabric in a tunnel oven and rolls it into a finished painted textile roll.  

As purchased, each section of the machine used a personal computer with an obsolete Windows XP operating system and a soft Allen Bradley Programmable Logic Controller (PLC) for the unwinding and painting of the fabric. Two physical Omron PLCs handled downstream control, one for the oven and conveying systems and another on the rewind section. A proprietary software run on the XP operating system utilized algorithms to control the paint from the spray heads and help to convert the customer’s CAD files into control commands, a very cumbersome process requiring much manual intervention.

Another problem impeding the retrofit plan was a tremendous lack of documentation and labeling. This coupled with obsolete controls, proprietary software and a burdensome workflow with no known support prompted Heytex to task EDC with improving the machine with an integrated hardware and software design.  

Solution

EDC’s approach was to streamline the control architecture ensuring that the PLC, drives and HMI were from the same manufacturer and would all be on the same communications network. Three disparate control programs were consolidated into one PLC, eliminating the need for a machine-based computer, soft PLC and monitor. The Siemens S7-1500 PLC and S120 drive platforms coupled with a 12-inch Comfort Panel were an excellent fit for this application. 

Siemens’ S120 Sinamics Smart line module and common DC-bussed drives provide energy saving load sharing across the six drives and is able to regen excess AC voltage back to the incoming power line. Line drives were previously controlled in a start/stop mode and could only run at other speeds by manually changing the internal drive parameters. The S120 system provided full speed control capabilities as commanded by the PLC over a ProfiNet network.

The S7-1500F failsafe PLC simplified safety component wiring, especially given that three new cable-operated switches (safety rope pulls) were installed at the Unwind Exit, Paint Booth Entry and Rewind, improving the overall safe operation of the line. All main control components communicated with the PLC over a single ProfiNet control network including six VFD and servo drives, two remote I/O hubs and a new 7” HMI located at the Rewind section.

In addition to the cable-operated switches, other mechanical upgrades included a specially designed tension control system for the Unwind, adapters to couple new servo motors to existing spray head linear actuators, a line speed encoder at the oven exit and a linear position transducer for accumulator feedback. The EDC Field Installation Team installed and wired the new elements on Line 2 and ensured their proper functionality.

As previously mentioned, EDC consolidated all PLC logic into one CPU that closely communicates with the new HMI and S120 drive system. A user-friendly HMI screen and a recipe system were incorporated to improve the operator’s experience running the line. An offline program to convert the customer’s CAD files to data the PLC could use for proper control of the spray heads was a crucial part of the upgrade. EDC’s Project Engineer wrote an open-source Java script/HTML interface that could be modified by anyone with those computer language skills, eliminating the proprietary nature of the previous software incarnation.

Another key element of EDC’s retrofit is their documentation. A full set of wiring schematics was created that included reference for all components, wire numbers and a terminal plan. The customer was given a physical binder with hard copies of the drawings and digital copies of the control programs, the CAD conversion program and component manuals. A Tosibox remote access module was installed and connected to the machine’s control network. When connected to the internet, this device provides an ultra-secure VPN tunnel for remote monitoring and troubleshooting.

Impact

The improvements EDC made on Line 2 were substantial. Heytex went from a non-operational line whose parts were being cannibalized to keep an adjacent line running to a fully functional, efficient line with a state-of-the-art control system. Improvements included:

  • Streamlined workflow making it easier to go from the customer’s drawing to product runs, eliminating a full set-up step
  • Open source programs that can be modified and improved by any qualified service provider, eliminating proprietary software
  • An energy-efficient control architecture that is rugged, orderly and fully documented without reliance on ever-changing personal computer hardware
  • Improved control of the Oven conveyor, Tensioner and Rewind motors including better accuracy and synchronization through all speed ranges 
  • Improved Accumulator control that prevents finished product from touching the floor as was the case during Rewind roll changeover
  • User-friendly operator interface screens with more relevant operational feedback, alarms, messages and maintenance screens 
  • New capability to switch between patterns in the middle of a single roll and stop and resume a pattern if there is an Estop or alarm, potentially saving hundreds of yards of material per year
  • Remote monitoring and troubleshooting capability which was utilized to its full potential one month after start-up when Heytex needed to recalibrate Line 2 for new material. EDC was able to support them remotely and avoid a costly service trip from New Jersey to Virginia.
  • A retrofit platform with documentation, programs and drawings that can be utilized to upgrade Line 1, ensuring production viability for years to come

To sum up the benefits of the project, EDC’s VP of Engineering Chuck Dillard said, “If you look back, only Line 1 was operable. Now both lines are running, and Line 2 runs more efficiently with higher throughput than the machine’s original design.”

Coating and Laminating Website Page Delivers Educational Content for Manufacturers Across the Country

Posted on by Georgia Whalen

Electronic Drives and Controls recently published a new website page on everything you need to know on coating and laminating as a manufacturer. 

Whether your machine is facing an issue (or multiple), not running at full speed, producing lower quality work than expected, or maybe just needs an upgrade and you’re not sure where to start, this page was created with you in mind. This educational article is supported by multiple case studies featuring relevant EDC projects that have brought success to manufacturers across the country.

 

To view the full website page visit below:

 

 

If your coating and laminating line’s throughput is rapidly decreasing or the machine is experiencing more downtime, there are a few relatively small strategies you can employ to take a bite out of the larger issues. Or if need be, it might be time to consider a retrofit for a fraction of the cost and in less time than it would take to install a more expensive, completely new line. How can you know for sure?

It’s time for you to master unwinds, rewinds, flying splices, printing heads, laminators, accumulators, and more. Navigate to the page today to learn more about coating and laminating and advance your manufacturing process with EDC’s guidance. Additional topics covered are common pain points, resolutions, upgrades, and best practices for coating and laminating machines, including how to know when it’s time for a full retrofit. 

If you need further help with your coating and laminating line, reach out to EDC today.

Electronic Drives & Controls, Inc. to Showcase Innovative Solutions for the Wire and Cable Industry at 2023 Interwire Trade Exposition

Posted on by Georgia Whalen

EDC Interwire event press release

EDC will exhibit at booth #1259 May 9-11 during the 2023 Interwire Trade Exposition, organized by The Wire Association International (WAI), to connect with wire and cable professionals and to share leading-edge solutions to industry pain points. 

Parsippany, NJ – April 18, 2023 – Electronic Drives and Controls, Inc. (EDC), a leading control system integrator and field service company for industrial automation and drive technology, today announced their attendance at the upcoming Interwire Trade Exposition at the Georgia World Congress Center in Atlanta, GA. EDC will be available May 9 and 10 from 10 am to 5 pm and May 11 from 10 am to 3 pm in exhibitor booth #1259 to discuss wire and cable manufacturing solutions with attendees and industry professionals.

“We are thrilled to be exhibiting at Interwire and sharing our expertise in AC & DC drives, PLCs and factory automation for the wire and cable industry with attendees,” said Vice President Chuck Dillard. “With over 50 years of experience in integrating new control systems and upgrading older equipment, we are able to tackle projects of any complexity. We have a top-notch engineering team to design, build and start-up projects, and a dedicated service support team to ensure our solutions continue to operate smoothly for years to come. Our track record of success in the wire and cable industry speaks for itself, and we look forward to showcasing our capabilities at the expo.”

With a deep understanding of wire and cable industry pain points, EDC engineers will be on hand to share the company’s industry experience and an understanding of the many obstacles wire and cable manufacturers face.  EDC has completed projects ranging from small upgrades to full retrofits, from dealing with obsolete drives or PLCs to excessive wire breaks and increased downtime, all with a tailored approach that prioritizes cost and timing.

The Interwire Trade Exposition provides a global resource for attendees to stay up-to-date with the recent developments and innovations in the industry, such as the growing importance of Industry 4.0, including the integration of IoT, Smart Manufacturing, and Artificial Intelligence in manufacturing processes. The conference promises to be an exciting opportunity for wire and cable manufacturing professionals to share knowledge and expertise, network with colleagues, and stay up-to-date with the latest trends and developments in the industry. 

During the two-day exposition, industry experts and professionals will converge to participate in panel discussions on key issues affecting the wire and cable workforce, copper supply and demand, and the outlook for the steel market. Attendees will have the opportunity to explore industry best practices, including wire break solutions, production developments, and approaches to case-by-case difficulties. 

To learn more and register for the event, visit https://www.interwire23.com/

 

About Electronic Drives and Controls, Inc.

Founded in 1968, Electronic Drives and Controls, Inc. (EDC) is a CSIA Certified control system integrator with deep domain expertise in the wire and cable industry. The company’s large field service team specializes in AC and DC drives, PLCs and factory automation. Family owned and operated for more than 50 years, EDC’s team of engineers and technicians has a vast experience integrating new control systems and breathing life into older equipment. EDC has the engineering capability to design, build, start-up and service projects from the sophisticated to the simple and the service support team on call 24/7/365 to keep it all running at peak efficiency from day one and for years to come. In addition to the company’s certification as a Siemens Solution Partner and a Rockwell Automation Recognized System Integrator, EDC is a factory authorized/factory trained service center for over 40 drive brands.  For more information, visit the company’s website, LinkedIn, Twitter, Facebook, and YouTube.

Electronic Drives and Controls’ Zack Fischer Earns Professional Engineer (PE) License

Posted on by Georgia Whalen

Project Electrical Engineer Zack Fischer of Electronic Drives and Controls (EDC) has earned his Professional Engineer (PE) license.

Parsippany, NJ – February 5, 2024 – Electronic Drives and Controls, Inc. (EDC), a leading control system integrator and field service company for industrial automation and drive technology, today announced that Project Electrical Engineer Zack Fischer has earned his Professional Engineer (PE) license. Fischer’s achievement marks an important milestone for both his professional growth and EDC’s ability to serve clients with even greater efficiency and expertise.

The Professional Engineer (PE) license is a prestigious credential awarded to engineers who meet rigorous educational, experience, and examination requirements. To earn this designation, engineers must obtain a relevant degree in engineering from an accredited four-year university, accumulate years of hands-on experience under a licensed PE, and successfully pass both the Fundamentals of Engineering (FE) and Professional Engineering (PE) exams. They must also secure multiple professional references, including sponsorships from licensed PEs who can verify their experience and qualifications.

Fischer joined EDC in 2013, starting in the Drives Service team before transitioning to the Systems Integration team in 2016. Fischer, a graduate of the New Jersey Institute of Technology with a degree in Electrical Engineering, pursued this certification not only to further his expertise but also to become the first licensed engineer in his family’s four-generation engineering legacy. In addition to his new PE license, Fischer has also completed the Siemens Global Technical Certification, earning a near-perfect score on his exam.

“We are incredibly proud of Zack’s hard work and dedication in achieving his PE license,” said Ed Sefcik, PE, Engineering Manager. “His technical expertise, problem-solving skills, and meticulous attention to detail have always made him an invaluable member of our team. This milestone enhances the level of service we can offer, allowing us to expedite critical project approvals and maintain full control over the certification process.”

About Electronic Drives and Controls, Inc.

Founded in 1968, Electronic Drives and Controls, Inc. (EDC) is a CSIA Certified control system integrator with deep domain expertise in the coating and laminating, and converting industries. The company’s large field service team specializes in AC and DC drives, PLCs and factory automation. Family owned and operated for more than 50 years, EDC’s team of engineers and technicians has a vast experience integrating new control systems and breathing life into older equipment. EDC has the engineering capability to design, build, start-up and service projects from the sophisticated to the simple and the service support team on call 24/7/365 to keep it all running at peak efficiency from day one and for years to come. In addition to the company’s certifications as a Siemens Solution Partner and a Rockwell Automation Recognized System Integrator, EDC is a factory authorized/factory trained service center for over 40 drive brands.  For more information, visit the company’s website, LinkedIn, Twitter, Facebook, and YouTube.

Takeaways and Highlights from Our Trip to Germany with Siemens

Posted on by Brittany Smist
[vc_row][vc_column][vc_single_image image=”2893″ img_size=”full”][vc_column_text]After getting back from a great trip to Germany, first and foremost we want to thank the incredible Siemens team for their hospitality, insights, and support throughout our visit. From coordinating meetings to sharing technical knowledge, they made the experience well worth the travel. A special thanks to:
  • Amer Abubaker – Amer shared a powerful personal story about his journey to U.S. citizenship and was passionate about bringing what he learned in Germany back home.
  • Kaitlin Scott – Drives Specialist who went above and beyond to organize logistics and social events for the U.S. guests. She also happens to be a top-notch engineer.
  • Pradeep Singh – Formerly with Siemens India, now based in Germany, Pradeep played a key role in coordinating the workshop and bringing marketing insight to the table.

While in Germany, the EDC team participated in two major events: Hannover Messe, the largest industrial automation fair in the world, and the SINAMICS Large Power Drives Workshop hosted at Siemens’ Motion Control HQ in Erlangen. Each offered something different—and both were valuable.[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]

Highlights from Hannover Messe

[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]We hit the ground running—literally—by heading straight from the airport into the massive halls of Hannover Messe, the world’s largest industrial technology trade show.

Our main focus was the Siemens Mega Booth, a 20,000-square-foot experience center showcasing innovations in digitalization, motion control, and system integration. We had the chance to walk through live demonstrations, talk directly with Siemens leadership, and take a closer look at some of their latest drive and control technologies.[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_single_image image=”2891″ img_size=”full”][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]A couple of technologies came up a lot during our time at the Siemens booth—both in demos and in casual conversations. These weren’t just marketing buzzwords; people were actively discussing how they’re being used and where things are heading.

Digital Twin

One of the technologies that came up again and again at the show was the digital twin. Basically, it’s a way to build and test a full version of a machine in software before you build anything in real life. You can simulate how the equipment will run, work out any issues ahead of time, and fine-tune the process—all without touching physical hardware.

It’s especially useful in situations where timing is tight. For example, a manufacturer launching a new product might need to go from design to production fast. With a digital twin, the production line can be modeled and optimized in advance so that when it’s time to build, everything runs smoothly.

This isn’t something we’re offering just yet, but it’s a space we’re keeping a close eye on. There’s real potential here for future projects where speed, precision, and testing ahead of time make a big difference.

Industry 4.0

Another big focus at Hannover Messe was Industry 4.0—basically, the push toward smarter, more connected factories. That includes things like machines that talk to each other, remote access for troubleshooting, real-time data tracking, and cloud integration.

These are things we’re already doing in a lot of our projects—especially when we’re working with ProfiNet, TIA Portal, and modern PLC/HMI systems. But it was great to see how Siemens is continuing to move the ball forward. There’s clearly more opportunity ahead for our customers to improve efficiency, cut downtime, and make their systems easier to monitor and support.

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Highlights from SINAMICS Large Power Drives Workshop Roundtable:

[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]The second part of our trip was the 2025 SINAMICS Large Power Drives Workshop, a smaller, more focused event held at Siemens’ Motion Control headquarters in Erlangen. Organized by Siemens GMC US and GMC HQ, this invite-only workshop brought together a handful of U.S.-based companies for in-depth technical discussions.

The smaller setting allowed for productive conversations and a better chance to get to know the Siemens team. We talked shop, shared challenges, and exchanged ideas over group sessions and a shared dinner. We’d also like to thank the full Siemens team who presented, facilitated, and made this event possible:

  • Pradeep Singh – Global Business Development, Vertical Metals
  • Fabian Kinner – Global Business Development, Vertical Testing Equipment
  • Kaitlin Scott – Business Development, Vertical Testing Equipment (USA)
  • Danny Schaefer – Head of GMC Vertical Sales Automotive, Tire, Battery, Metals & Paper
  • Thomas Tichatschke – Head of Technical Consulting, Application Support & Simulations
  • Yorck Lange – Principal Technical Consultant, Large Power Drives
  • Fabian Perner – Head of Sales Americas
  • Alexander Stukenkemper – Head of Business Development Verticals & Segments
  • Shashikant Shivajirao Ghorpade
  • Amer Abubaker
[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_single_image image=”2892″ img_size=”full”][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]This event also reinforced how aligned our work is with Siemens’ motion control offerings. At EDC, our integration work regularly involves:
  • PLCs: S7-1500, S7-400, S7-1200, ET-200SP, ET-200MP
  • HMIs / Interfaces: Comfort Panel, Unified Comfort, Nanobox
  • Drives: S120 SINAMICS, S210, G120, G120C, V90, 6RA80 DC
  • Motion: S120 Simotion, 1FT7 & 1FK7 servo motors, 1PH8 asynchronous motors, Simogear
  • Safety & Comms: ProfiSafe, ProfiNet
  • Software: TIA Portal, WinCC
  • Legacy Conversions: S5 PLCs, 6SE70 Masterdrives, Micromaster, 6RA70 DC drives, Profibus, and more

Looking back, this trip was a valuable opportunity to deepen our Siemens relationship, see where the technology is headed, and bring back insights we can apply to EDC projects going forward. We’re grateful to the Siemens team for the warm welcome—and we’re looking forward to what’s next. 

Learn more about our Siemens capabilities here »[/vc_column_text][/vc_column][/vc_row]

Case Study: Precision in Tin Plating

Posted on by Brittany Smist
[vc_row 0=””][vc_column 0=””][vc_single_image image=”2908″ img_size=”full”][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]A major metals processor in the Midwest faced a significant challenge in modernizing its tin plating line to enhance productivity, consistency, and operational efficiency. Confronted with the complexities of integrating advanced automation, maintaining consistent product quality, and adapting to a newly relocated plant environment, they turned to Electronic Drives and Controls (EDC) for a custom solution. Using Siemens S120 drives, Fisher Scope X-Ray technology, and custom-engineered edge guide systems, EDC delivered a solution that improved line speed, product quality, and operational safety.[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]

Introduction

[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]Tin plating is a critical process in the metals industry, most commonly used to enhance the corrosion resistance, conductivity, and overall durability of metal products. At a high level, tin plating involves applying a thin layer of tin to a metal substrate—often steel or copper—through an electrochemical process. This protective coating not only improves the metal’s appearance but also enhances its solderability and resistance to oxidation. In industrial applications, consistent tin thickness is crucial, as even minor variations can significantly impact product performance and end user satisfaction.

EDC’s client on this project is a major multinational metals company known for its high-quality metals products. To remain competitive and to address operational challenges, they sought to upgrade one of its tin plating lines. The project’s primary objectives were to replace operator-dependent processes with automated systems that could consistently control tension, line speed, and tin thickness—key variables that directly impact product quality and throughput. Additionally, the relocation of the line to a different plant added complexity, requiring a solution that could adapt to changes in layout, wiring conditions, and equipment positioning in order to minimize downtime.

Line Overview: The line begins with an Uncoiler, which feeds a metal strip through a wiper pad and then into a series of hydrochloric acid and flux baths. After each bath, the strip is wiped to remove excess fluid. From there, the strip passes through a Bridle that helps maintain tension before entering a molten tin bath, where plating occurs. As the strip exits the tin bath, high-velocity air wipes remove excess tin and ensure a consistent coating. The positioning of these air wipes is critical, as even slight misalignment can lead to variation in tin thickness. Two edge guides—one before the tin bath and another before the Recoiler—help ensure that the strip stays properly aligned. A second Bridle is positioned after the vertical tower, just before the Recoiler, which winds the finished strip for downstream handling.

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Problem

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Operational Inconsistency and Operator Dependency

The existing system relied heavily on manual adjustments by operators, which led to variability in product quality and throughput. This challenge was further compounded by staffing concerns. With experienced operators nearing retirement age, it was difficult to find reliable replacements to perform the nuanced manual processes required to operate the line’s equipment successfully.[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]

Complexity of Relocation

The project involved reconfiguring and relocating the tin plating line to a different plant, introducing significant rework not typically required for a basic line upgrade. The move led to alignment and wiring challenges that required recalibration and troubleshooting. EDC also had to account for differences in power distribution, control panel placement, and new Uncoiler and Recoiler sections—all of which affected how the system needed to be configured and integrated in the new space.[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]

Tight Scheduling Constraints

The project was executed under strict scheduling constraints. EDC created a strategic plan to sequence the installation and commissioning phases. This minimized downtime and kept the project on track, ensuring the line would be operational according to the required timeline.[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]

Safety and Environmental Challenges

The production environment introduced its own hazards, including hydrochloric acid (HCL) baths that created a highly corrosive atmosphere. These conditions posed risks to both equipment and personnel, prompting the use of advanced safety controls such as interlocks, fail-safe relays, and physical barriers to protect workers and meet industry safety requirements.[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]

Solutions Implemented

[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]To overcome the complex challenges posed by the tin plating line project, EDC implemented a series of advanced automation solutions tailored to this clients’ unique operational requirements. These solutions not only addressed the immediate issues of operational inconsistency, safety, and relocation but also laid the groundwork for scalable and adaptable production capabilities into the future.[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]

Smart Automation with Real-Time Monitoring

At the heart of the modernization effort was the integration of advanced Siemens drive technology and intelligent visualization systems. This architecture provided precise, flexible control of line speed, tension, and tin thickness.

One of the most advanced features of the project was the addition of the Fisher Scope X-Ray. Previously, operators would manually measure and adjust tin thickness—a process prone to delays and human error. The new system continuously monitors the coating thickness and communicates directly with the HMI to maintain optimal output in real time—removing the need for operator intervention and significantly improving consistency.

Installed Components:

  • Siemens SINAMICS S120 Drive System 
  • Siemens CU320-2 PN Control Unit
  • Siemens SIMATIC HMI TP1200 Comfort Panel – 12″ widescreen with Profinet interface, designed for high-performance visualization applications
  • Fisher Scope X-Ray – for continuous tin thickness monitoring and automatic adjustment
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Edge Guide Control and Tension Management

Maintaining strip alignment and tension was a key challenge, especially after this client replaced the existing Uncoiler with a heavier, hydraulic model from storage to accommodate larger coils. This modification required changes to the control system to ensure consistent material handling and stable process control. EDC developed a custom edge guide system using light bar-type sensors and actuators to maintain precise strip positioning throughout the process—from the Uncoiler, through the Bridles, and on to the Recoiler. Together, these systems ensured repeatable tension control and reduced unplanned maintenance.

Installed Components:

  • Edge Sensor (model DSE-41)
  • Edge Guide Actuator (model GMA-D1-5-100.1-ISCT-A)
  • Programmable Oscillators
    Self-contained Edge Guide Controllers 
  • Hydraulic Uncoiler
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Advanced Drive and Motor Integration

Marathon AC vector motors and Siemens drives were used to power key sections of the line, including the Bridles and Recoiler. This setup delivered improved speed control, synchronization, and system reliability while reducing maintenance demands.

Installed Components:

  • Marathon AC Vector Motors with Encoder Feedback
  • Siemens SINAMICS S120 Drive System
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Enhanced Safety and Risk Management

Operating near hydrochloric acid (HCL) baths introduced corrosive and hazardous conditions. To protect personnel and equipment, EDC implemented a layered safety architecture including light curtains, load cells, emergency stop stations, and a dual-channel safety relay—all tied into the Siemens control system for real-time monitoring and safe stopping.

The team also conducted risk assessments throughout the project, enabling them to plan proactively for issues and keep the installation on track despite relocation complexities.

Installed Components:

  • Light Curtains 
  • Load Cells 
  • Safety E-Stop Relay 
  • E-Stop Stations and Reset Button
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Outcomes and Results

[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]The solutions implemented on the tin plating line are designed to deliver significant operational improvements. Based on the scope of work and strategic upgrades, the expected results include:
  • Enhanced Product Quality: With real-time monitoring and automated adjustments via the Fisher Scope X-Ray, the tin plating process is expected to achieve highly consistent thickness across the entire strip. This will minimize material waste and ensure compliance with stringent customer specifications.
  • Increased Productivity and Efficiency: The integration of Siemens S120 drives and smart automation reduces reliance on manual operator adjustments, enabling a more streamlined and repeatable process. This is anticipated to result in higher throughput and decreased production downtime.
  • Improved Tension Control and Material Handling: The upgraded edge guide control system and programmable controls ensure better strip alignment, reducing defects and preventing operational inconsistencies that previously led to production delays.
  • Operational Safety Enhancements: The introduction of dual-channel safety circuits, light curtains, and load cells mitigates risks associated with the hostile HCL acid bath environment. These safety improvements contribute to a safer working environment for plant operators.
  • Adaptability for Future Expansion: The system’s modular design and ability to accommodate auxiliary equipment modifications mean the processor can scale operations or make further refinements without major overhauls. If successful, similar technology may be utilized on other tin plating lines within the client’s operations.
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Lessons Learned and Future Outlook:

[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]The tin plating line project required EDC to remain flexible and hands-on throughout. From troubleshooting wiring and alignment issues after relocating the line, to adjusting control logic to accommodate new equipment added by the client mid-project, the team adapted quickly to keep the installation moving forward, ensuring that new components were incorporated with minimal turn-around time.

Close collaboration, proactive communication, and contingency planning also played critical roles. When client-side delays arose, EDC maintained progress by working on parallel tasks, providing remote support and adjusting timelines to keep the project moving forward without compromising its long-term objectives.

The improvements made through this modernization are expected to deliver measurable gains in product quality, efficiency, and safety. Using state-of-the-art Siemens technology and advanced control systems, EDC provided this client with a scalable solution that positions their tin plating operation for continued success. The approach taken in this project will also serve as a model for similar upgrades across other lines within this metal processor’s operations.[/vc_column_text][/vc_column][/vc_row]