Control Systems
Engineering
Nationwide Control System Solutions for Manufacturers
At Apex Controls, we provide control systems engineering services for manufacturers and industrial facilities nationwide. Our experienced engineers design, integrate, modernize, and optimize control systems to improve efficiency, reliability, safety, and performance.
From new control system implementation to legacy system modernization, Apex provides the engineering and technical expertise needed to develop reliable, scalable solutions tailored to your operation, plant standards, and long-term goals.
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More Than PLC Programming
Control systems are more than PLC programming and automating a machine. A successful system requires the right architecture, hardware, networks, control strategy, operator interface, safety systems, and data infrastructure.
Apex combines controls engineering, programming, electrical expertise, panel building, and field experience to provide complete control system solutions.
Our team works closely with your engineers, operations personnel, and maintenance teams to develop systems that perform reliably and can be maintained and expanded for years to come.
One Integrated System.
Every layer engineered to work together.
Modernize Without Starting Over
Legacy control systems can become difficult to maintain when hardware is obsolete, software is unsupported, or replacement components are no longer available.
Apex can modernize existing control systems while minimizing disruption to production. We evaluate your existing system and develop an approach based on your equipment, production requirements, and future goals.
Complete Control System Solutions
From system architecture and PLC programming to plant-wide visualization, safety, data, and utility controls, Apex provides the engineering expertise needed throughout the control system lifecycle.
Control System Design & Architecture
Apex engineers control systems based on your process requirements, plant standards, safety requirements, and long-term objectives.
- Control system architecture
- PLC architecture
- HMI & SCADA architecture
- I/O architecture
- Industrial networking
- System communications
- Hardware selection
- Control logic design
- Process control
- System integration
PLC & HMI Engineering
Our engineers develop applications that provide reliable control, clear operator information, and consistent system performance.
- PLC programming
- HMI development
- Process control logic
- Machine sequencing
- Recipe management
- Motion & drive integration
- Equipment communications
- Operator interfaces
SCADA Systems
Apex designs and implements SCADA systems that provide real-time monitoring, control, data collection, and visibility across your operation.
- SCADA architecture
- HMI/SCADA development
- Real-time monitoring
- Historical data
- Trending
- Alarming
- Production dashboards
- Reporting
- Equipment integration
- Plant-wide visualization
- Data collection
Control System Modernization
Apex modernizes aging control systems when hardware becomes obsolete, software is unsupported, or replacement components are increasingly difficult to obtain.
- PLC migration
- Obsolete PLC replacement
- HMI upgrades
- SCADA modernization
- Panel modernization
- Network upgrades
- Legacy system replacement
- Controls documentation
- Startup & commissioning
- Support & optimization
Industrial Data & Smart Manufacturing
Apex helps collect and organize manufacturing data so it can improve visibility, decision-making, and operational performance.
- Machine data collection
- Historian systems
- Production dashboards
- OEE
- Downtime tracking
- Production reporting
- Traceability
- Industrial IoT
- Data contextualization
- MES integration
- ERP integration
- Enterprise connectivity
Safety Systems
Apex engineers provide safety system design and integration based on your application requirements and applicable industry standards.
- Safety PLCs
- Safety systems
- Safety architecture
- Machine Risk Assessments
- Safety instrumented systems
- Safety logic
- Safety validation
- Functional safety engineering
Apex engineers are TÜV-certified at engineer and technician levels.
Alarm & Process Optimization
Apex evaluates and optimizes alarm structures and process control strategies to improve system performance and operator response.
- Alarm assessment
- Alarm rationalization
- Alarm prioritization
- Nuisance alarm reduction
- Process control logic
- Sequencing
- Interlocks
- PID control
- Process optimization
Plant Utility Controls
Apex provides control system engineering for the utilities and infrastructure that support your manufacturing operation.
- Ammonia systems
- Glycol systems
- Air handling units
- Boiler systems
- Chilled water
- Compressed air
- Utility monitoring
- Energy management
Control Systems for New & Existing Facilities
Whether you're building a system from the ground up or improving infrastructure that's already in place, Apex can support the complete project lifecycle.
New Control Systems
Apex can support new control system projects from scope development and system architecture through engineering, programming, testing, commissioning, and startup.
Existing Control Systems
We evaluate and improve existing systems through modernization, troubleshooting, SCADA upgrades, alarm optimization, network improvements, PLC migrations, and system integration.
Designed Around Your Standards
Every facility has its own standards, preferred technologies, documentation requirements, and operating practices. Apex works with your corporate and plant standards to ensure the control system integrates properly into your existing operation.
If standards have not yet been established, our team can help develop standards that support consistency, maintainability, and future projects.
A Collaborative Engineering Approach
At Apex Controls, we prioritize open communication throughout every project. Our engineers work closely with your team, provide regular updates, track issues, and incorporate feedback throughout the design and implementation process.
Our detailed approach helps identify potential issues early, reduce on-site changes, and ensure the completed control system meets your requirements.
Need to Design or Modernize a Control System?
Whether you are implementing a new control system, modernizing an existing system, upgrading SCADA, replacing obsolete controls, or looking for ways to improve plant performance, Apex Controls can help.
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