Industry & manufacturing
Keep lines running, replace ageing controls and see where every kWh goes
AMADSAS automates production plants end to end — instrument mounting, PLC, SCADA and DCS, drives and control panels — and connects lines and utilities to one centralised monitoring platform for traceability, energy and maintenance data.
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Operating challenges
Most plants run a mix of controllers installed over decades. Lines keep producing, but spare parts become scarce, data stays locked in individual HMIs and nobody can say what a tonne or a unit actually costs in energy.
Our industrial work covers instrument mounting, field instrument integration with PLC and SCADA, DCS implementation, testing and handover, and the supply of PLCs, HMIs, VFDs and soft starters. We build chiller, boiler, furnace, AHU, VFD and PCC/MCC panels in our own manufacturing units.
References include a 10,000-tag centralised system for Tata Steel, assembly-line centralisation and traceability for Royal Enfield and Comstar, boiler automation for Thermax and Shah Paper, and MV drive and HT switchgear integration for Sona Alloys.
- 01
Ageing and obsolete control systems
PLCs, DCS and drives that are out of support put production at risk. Migration has to happen on a running plant, with I/O, logic and HMI screens moved without losing what the old system did.
- 02
Data trapped in individual machines
Each line has its own HMI and its own records. Without centralised data, production, downtime and quality traceability depend on manual logs.
- 03
Energy and utility costs
Compressors, chillers, boilers and drives draw most of a plant’s energy. Without metering by area and by utility, savings cannot be targeted or proven.
- 04
Process control on critical equipment
Boilers, furnaces, crushing plants and treatment plants need interlocks, sequencing and alarms that operators trust, with redundancy where a trip stops the plant.
- 05
Shutdown windows for retrofits
Retrofit work is squeezed into planned shutdowns. Panels must arrive tested, cabling must be ready and commissioning must finish inside the window.
How we address them
- 01
Site study and I/O survey
We walk the plant, record existing controllers, instruments and drives, and define the I/O list, network and migration sequence with your engineering team.
- 02
Panel engineering and FAT
Control, drive, PCC/MCC and MV panels are designed in AutoCAD/EPLAN, built in our manufacturing units and tested at FAT with your engineers before dispatch.
- 03
Installation, cut-over and commissioning
Our teams mount instruments, lay and terminate cables, run loop checks and commission PLC, SCADA and DCS logic within the agreed shutdown window.
- 04
Centralise and support
Lines and utilities are connected to the centralised monitoring platform with historian, analytics and reporting, then supported under AMC.
Solutions for this sector
- Plant AutomationPLC, DCS and SCADA engineering, drives, legacy migration and IoT from design to commissioning.
- Control Panels & Electrical InstallationMCC, PCC, APFC, VFD, MV and IEC 61439 panels and E-House, built in-house and installed on site.
- Test Benches & Load BanksCustomised test facilities and load banks for rotating machines, power electronics and components.
- Centralised MonitoringRedundant SCADA, historian and compliance reporting that puts every site system on one screen.
- Energy, Load & Lighting ManagementEnergy metering, PUE tracking, load control and smart lighting with dashboards and reports.
Delivered projects
| Client | Sector | Scope | Year |
|---|---|---|---|
| Tata Steel | Steel | Centralised system, 10,000 tags | 2019 |
| Tata Motors | Automotive | Centralised system, EMS, BMS and utilities | 2023 |
| Royal Enfield | Automotive | Assembly-line centralisation and traceability | 2022 |
| Comstar | Automotive | Assembly-line centralisation and traceability | 2020 |
| L&T | — | Centralised system, server, historian, analytics and reporting | 2023 |
| Polyhose | — | Centralised system, server, historian, analytics and reporting | 2022 |
| Murugappa | — | Centralised system, server, historian, analytics and reporting | 2021 |
| Sona Alloys | Steel | MV drive and HT switchgear integration | — |
| Bhushan Steel | Steel | ETP and bag filter automation | — |
| MDNL | Metals | Remelting furnace | — |
| thyssenkrupp | — | NALCO crushing plant | — |
| Thermax | Boilers | Boiler automation | — |
| Shah Paper | Paper | 30 TPH boiler | — |
| Ruby Macon | Paper | Paper mill and environment treatment plant | — |
| Indorama | Textile | — | — |
| Century Enka | Textile | — | — |
| VW | Automotive | — | — |
| Cummins | OEM | — | — |
| Godrej | — | — | — |
| Dipak Fertilizer | Fertiliser | — | — |
| Sterlite | Process | — | — |
| Q2 Engineering, Malaysia | Process | — | — |
| Ador / EIL | Gas handling | Gas handling automation | — |
| HPCL, Jammu | Oil and gas | Terminal automation | — |
Frequently asked questions
Can you migrate our legacy PLC or DCS without a long shutdown?
Yes, that is the usual brief. We survey the existing I/O and logic, prepare and test new panels and software at FAT, and plan the cut-over in stages that fit your shutdown windows.
Which controller brands do you work with?
We are an authorised partner for ABB, Inovance, Kyland, Helmholz, KOENIG, Klemsan and CUBIC, and we integrate other makes already installed in your plant over standard protocols such as Profinet, EtherNet/IP, Modbus TCP and OPC UA.
Do you manufacture the panels yourselves?
Yes. Control, VFD, PCC/MCC, APFC, MV and IEC 61439 CUBIC modular panels are built in our manufacturing units, including CNC punching, bending, laser cutting, wiring, testing and QA.
Can you provide production traceability across assembly lines?
Yes. Assembly-line centralisation and traceability systems are in operation for Royal Enfield and Comstar, collecting line data into a central server with historian and reports.
Do you provide redundant control systems?
Yes, where the process requires it. Redundant controllers, servers and network rings are part of our standard scope options for critical equipment.
Let’s start by understanding your facility
Send us a short description of the site and its current systems, and an engineer will come back with clear next steps.