Metals
Controls and Automation for Metals
We provide controls and automation engineering for metals processing facilities — from rolling mills and coating lines to pickling and continuous strip processing. Our metals industry work centers on drive system upgrades and PLC migrations for high-demand production lines, delivered within the tight shutdown windows these facilities require.
Rolling Mill & Coating Line Drive Upgrades
Replacement of obsolete drive systems on rolling mills, coating lines, and strip processing equipment with modern platforms, including complete controls design, DCC chart mapping and conversion, new network architecture, and integration with existing PLCs and HMIs — all while retaining existing motors to reduce cost. We simulate drive operation in-house with real motors and encoders before site work begins.
Drive Retrofits
DCC Conversion
Simulation
Process Line PLC & Controls Upgrades
Migration of aging PLC and drive platforms on continuous processing lines from obsolete or third-party controllers to modern platforms. Our upgrades include optimized motion control, increased process speeds, automation of previously manual maintenance tasks, and advanced HMI design with detailed diagnostics for interlocks, drive feedback, and networking.
PLC Migration
Process Optimization
HMI Development
Tight-Turnaround Commissioning
Many metals facilities can only afford minimal downtime for controls upgrades. We plan and execute migrations within compressed shutdown windows through extensive pre-site simulation, detailed test plans, 3D cabinet modeling for space-constrained installations, and rigorous on-site checklists.
Commissioning
Shutdown Planning
Risk Reduction
Metals Case Studies
How CSI replaced legacy Reliance drives and Rockwell PLCs with a modern Siemens S120 drive system and safety PLC on an active steel pickling line — delivering improved diagnostics, regenerative energy savings, and enhanced safety architecture within a two-week shutdown window.
How CSI replaced 18 obsolete drives on a roll forming line with a modern Sinamics S120 system — upgrading the electrical backbone of the machine while preserving the existing mechanical infrastructure, field devices, and panel hardware.