Projects

Procontrol Systems has worked on a large number of projects in all manner of industries including:

Listed below are some of our highlighted projects and clients.

High-Speed Custom Made Assembly Machines

Procontrol Systems is a highly competent machine builder using the latest technologies. These custom machines are designed and built from scratch for a specific product. Our focus is on precision, speed and quality from start to finish. Procontrol performs the complete design, build and commissioning of these machines reducing the stress and time wasted for the client!

Syringe Assembly Machine

This complex machine was designed to produce tens of millions of syringes per year. With a very low cycle time, this was achieved successfully. It is one of Procontrol's proudest achievements. Click for more info and a video!


Plastic Parts Assembly Machine 1

In addition to producing tens of millions of parts per year, this machine can also make two types of products. With every part working synchronously this machine certainly looks impressive. Click for more info and a video!


Plastic Parts Assembly Machine 2

This small machine was originally built for one product, but then modified to accomodate two products all on a tight budget. It shows the versatility of design and application by our engineers! This similarly produces tens of millions of parts per year.



BHP Billiton Olympic Dam

BHP is a the largest mining company in the world. At Olympic Dam near Roxby Downs in the SA outback BHP mines copper, uranium, gold and silver.

Procontrol is involved with BHP at Olympic Dam providing expertise and support to their electrical engineering team. Our engineers have assisted in commissioning major projects, upgrading automation equipment and improving efficiencies in the plant.


Amcor

Amcor Glass is a glass bottle manufacturer and makes in excess of 1 million bottles daily. Procontrol continues to support Amcor with senior service and performs upgrades to hardware/software and maintenance support as required.

Commissioning of Warehouse Overhead Conveyor

A new overhead conveyor system transports bottles stacked on pallets 100 metres across a warehouse on two conveyor lines. Extensive PLC and HMI improvements were engineered to ensure the reliability of the system and minimise downtime.


Adelaide Brighton Cement

Adelaide Brighton Cement is a manufacturer of cement, lime and pre-packaged dry-blended products and operates throughout Australia.

Control System Audit

An audit of the entire control system for their Angaston plant revealed what changes had been made over the years, exactly what equipment their control system included, and what spares should be maintained. Procedures for making changes to their control system programs were coupled with a 'Change Register' to let other users of the system know what changes had been made.

Tyre Slip Monitoring

ABC required a method of accurately measuring the rotation time of both the Kiln and a Kiln Tyre. This method calculates the Tyre Slip distance, which was trended with alarms on Citect to provide an early warning system. This early warning allows the operators to take corrective action before any (expensive) damage to the kiln occurs.

Slurry Density Monitoring

ABC required another monitoring method this time to measure the density of the slurry exiting the slurry mill. Measuring this reveals the percentage water in the exit slurry. A precision controlled water valve was installed, which is able to finely adjust the amount of water maintaining a constant density in the slurry. The result is a better control of the manufacturing process downstream of the slurry mill.


General Motors Holden

GMH has been a client for many years and we proven ourselves working in a high pressure continuous production environment.

White Body/Painted Body Storage Facility

This project involved the storage and sorting of unpainted and painted car bodies ready for distribution to New Enamel Paint Shop or Final Assembly workshops. It included a monorail type conveyor consisting of 15 storage lanes, a recirculation lane, white body entry and exist zones, 4 body transfer lifts, painted entry and exist zones, 5 body transfer lifts, empty carrier return zones and carrier maintenance spur zones.

P-Line Mezzanine Conveyor

A new overhead Mezzanine Accumulating Conveyor including a new Lift Tower, Drop Tower and Turntable all synchronised into the existing Body Shop floor conveyors. These are all controlled by an Allen Bradley Control Logix PLC with multiple VSDs, touchscreens and associated safety systems.

NEPS Colour Changer Project

The design and development of a complex colour tracking system throughout the NEPS facility to ensure the correct paint colour is applied to the correct body.


Patawalonga Lake System

The PLS is an automated system operating the Glenelg barrage gates at the southern end of the lake and the gates in the weir at the northern end. The primary role of the system is to control water level circulation through the lake based on the rise and fall of the sea tide. Safety is a high priority because of the potential to flood adjacent property and damage boats in the marina, so the system prevents high tides and stormwater flows from entering the lake.

Procontrol has been involved in the last few years providing programming support for the PLCs and SCADA, thoroughly going over and testing every aspect of the system. Procontrol is also coordinating the modernising of the existing automation hardware to ensure maximum reliability and minimum response times.


Safety Medical Products

Safety Medical Products (Safetymed) is a pharmaceutical company with an emphasis on safety of medical equipment. The syringe assembly machine described at the top of this page was built for them.


Futuris

Futuris supply seats, Heating Venting and Cooling systems (HVAC) and carpeting to GMH in Adelaide. Some of the more prominent work done includes:

Assembly Line Traceability System

A data management system was developed to provide access to assembly data for every product built, and to log safety critical torque data and test results to a central database. In addition, a SCADA network consisting of nine HMI stations was installed for operators to view and update QA data, and to step operators through build/test procedures. The development of a web interface provided restricted access for managers and engineers to information stored on the central database.

Safety Critical Part Verification Vision System

Utilising the latest vision products and methodologies, a test machine was developed for the purposes of verifying correct operator assembly of a safety critical product. The vision system had to tolerate a large range of product variation and still provide a failproof pass.



Cutler Brands


Procontrol has been instrumental in making Cutler Brands efficient and effective in labelling bottles. Right from the first commissioning job we have automated and streamlined their production processes. Our first job was to design and program the entire control system for their palletising and Lehr bottling lines.



Dayco

Procontrol have been involved in the research and development of Dayco's V-Fold belt filter presses for many years. These innovative filtering systems work well and continue to gain market share.