Plastics Processing Equipment Controls & Automation
Plastics processing facilities depend on reliable motor drives, electronic controls, and automation systems to maintain consistent production, precise equipment operation, and product quality. When these components malfunction, production can slow or stop, resulting in costly downtime.
Control Concepts provides troubleshooting, repair, and upgrades for industrial electronics and automation controls used in plastics processing equipment in Houston, Texas.
We service control systems used in a variety of plastics manufacturing processes, including:
- Extrusion
- Injection molding
- Reaction injection molding
- Blow molding
- Thermoforming
- Transfer molding
- Compression molding
We repair and upgrade controls for existing equipment and help replace obsolete components with modern control systems. Depending on the application, these upgrades can improve equipment reliability, process control, diagnostics, and production flexibility.
With more than 40 years of experience in industrial electronics and automation, Control Concepts provides technical support for both modern and legacy plastics processing equipment.
Our capabilities include:
- Electrical installation
- Onsite equipment testing
- Field modifications
- Industrial control system troubleshooting
- Motor drive and electronic controls repair
- Automation upgrades and retrofits
Common Plastics Processing Methods
Plastics manufacturing uses several processing methods, each with different equipment and control requirements. Automated systems help regulate temperature, pressure, motor speed, timing, and other operating conditions throughout production.
Extrusion: Plastic material is heated and forced through a die to create continuous products such as tubing, film, sheets, rods, and profiles. Electronic controls regulate screw speed, heating zones, and other process conditions.
Injection Molding: Plastic material is heated until it can flow and is injected into a closed mold under pressure. Precise control of temperature, injection pressure, screw movement, and cycle timing is essential for consistent production.
Reaction Injection Molding: Reactive liquid components are mixed and injected into a mold, where a chemical reaction causes them to polymerize and form the finished part. Accurate metering, mixing, and process timing are important for consistent results.
Blow Molding: Heated plastic is formed into hollow products, such as bottles and containers, using pressurized air. Automated controls coordinate heating, mold operation, air pressure, and cycle timing.
Thermoforming: Plastic sheets are heated until pliable and formed over or into molds using vacuum, pressure, or mechanical assistance. Temperature and forming-cycle controls help maintain product consistency.
Transfer Molding: Typically used with thermosetting materials, transfer molding moves heated material from a chamber into a closed mold under pressure. Process controls regulate temperature, pressure, and curing conditions.
Compression Molding: Plastic material is placed into a heated mold and compressed into the desired shape. This process is commonly used with thermosetting materials and relies on controlled temperature, pressure, and curing time.
Although these processes differ, they rely on industrial drives, sensors, controllers, and other automation components to maintain repeatable operations. When these systems fail, Control Concepts can help identify the problem and determine the appropriate repair or upgrade.
Plastics Processing Equipment Upgrades & Retrofits
Older plastics processing equipment can remain productive for many years, but obsolete drives, controllers, and electronic components can make repairs increasingly difficult. Modernizing existing controls may provide a practical alternative to replacing an entire machine.
Control Concepts provides industrial equipment upgrades and retrofits to help improve the performance and maintainability of existing plastics processing systems.
Depending on the application, control system upgrades may offer benefits such as:
- Improved equipment reliability
- Reduced unplanned downtime
- Better fault identification and diagnostic information
- Real-time operating data and performance monitoring
- More precise motor speed and process control
- Easier troubleshooting and maintenance
- Improved integration with existing automation systems
Properly designed upgrades may also reduce energy consumption when motor operation and other process functions can be adjusted to match production requirements.
Emergency retrofit assistance is available for critical equipment failures. Project timing and completion depend on the equipment, replacement component availability, and scope of work.
Our Plastics Processing Drive Repair Process
Troubleshooting motor drives and electronic controls requires evaluating both the equipment and its operating conditions. A drive fault may originate within the unit or result from problems elsewhere in the machine or electrical system.
Depending on the equipment and reported problem, our repair process may include:
- Inspecting motor drive terminals and electrical connections for damage or poor connections
- Testing applicable power components, including diodes and insulated-gate bipolar transistors (IGBTs)
- Checking incoming power, current measurements, and output frequency under appropriate test conditions
- Reviewing drive parameters, fault history, and operating settings
- Backing up available programming and configuration data before making changes
- Performing controlled functional testing, including jog operations when appropriate
Our technicians evaluate the complete drive application to identify the underlying cause of the malfunction and determine the appropriate repair or corrective action.
What Plastics Processing Controls Do We Service?
Control Concepts services a wide range of industrial electronics and automation components used in plastics manufacturing equipment.
Our capabilities include:
We work with equipment from a wide range of manufacturers. Visit our Brands Serviced page for more information.
Custom Control Panels for Plastics Processing Equipment
Control Concepts designs and builds custom industrial control panels to UL 508A standards for plastics processing equipment and other industrial automation applications.
Our panel shop capabilities include:
- Industrial control panel design
- Panel fabrication and assembly
- Electrical drawings and component selection
- Control programming and integration
- Quality control testing and verification
- Installation and field support
We begin by reviewing the equipment requirements and intended application. From there, we establish the necessary electrical ratings, develop panel designs and electrical drawings, and build custom panels based on the approved specifications.
Completed panels undergo appropriate inspection and testing to verify their construction and functionality before installation or commissioning.
Custom control panels can support equipment upgrades, replacement of obsolete controls, and integration of new automation components into existing plastics processing operations.
Learn more about our industrial control panel design and fabrication services.
24/7 Plastics Processing Equipment Controls Repair
Unexpected equipment failures can interrupt production schedules, affect product quality, and create costly delays for plastics manufacturing facilities.
Control Concepts has provided 24-hour industrial electronics service since 1984. Our technicians offer emergency troubleshooting and repair support for plastics processing equipment drives, electronic controls, and associated automation systems.
Based in Houston, Texas, we work to respond promptly to equipment problems and help customers restore reliable production operations.
Learn more about our 24/7 emergency industrial electronics repair and field service.
