Process Control and Plant Automation


Inspiring Better Communities with Better Plants and Facilities

Our technical experience provides clients reliably engineered solutions, and our relationships bring partnership and care to inspire businesses and communities. Through process control and plant automation systems, we create more efficient systems that impact your bottom line, which enables your plant or facility to bring a positive impact on the community.

Hallam-ICS is an experienced control system integrator for companies looking to solve their most pressing challenges with facility and manufacturing plant automation systems. Customers rely on Hallam-ICS to advise on and solve production challenges with an unbiased approach to recommending the best technology platform, ultimately improving throughput and creating more profitable operations. With in-house experts that work as an extension to your team, we understand your goals to create the best possible solution and can design, build, and program your plant automation system from start to finish. 


  • Control System Integration
  • Instrumentation & Installation
  • Instrument Calibration
  • Panel Fabrication
  • Documentation
  • Software Development
  • Manufacturing Intelligence
  • OT/IT Cybersecurity

Our Expertise

  • Regulated Environments / Process
  • Advanced Life Safety
  • Facilities Systems
  • Energy Management


  • Technical Expertise
  • Industry Experience
  • Maximizing Investments
Rockwell Automation Recognized System Integrator

Learn More About Our Process Control & Plant Automation Services

Case Study: Process Control System

BYK USA Inc. has expanded their specialty chemical production operations by constructing a new, fully automated manufacturing facility. To meet customer demands, BYK stressed the importance of having a flexible system that could deliver a range of batch sizes and was able to easily facilitate recipe changes. To achieve these goals, BYK required that the process control system be designed and implemented in accordance with the S88 Batch Programming Standard.

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BYK case
Upgrading obsolete

White Paper: Upgrading Your Obsolete Control System While Keeping Your Plant Running

This white paper explores some of the key questions that should be asked prior to planning an upgrade to an obsolete control system.  

  • What PLC hardware will the new automation system use?
  • How can your operators effectively run your plant during an automation system conversion?
  • Running your plant with old and new hardware at the same time?

Download White Paper


Guide: Introduction To Batch Processing With S88

Learn more about batch processing with S88 and get better results with the help of this detail-rich guide. It covers:

  • The S88 Standard & Benefits of a Good S88 Design
  • Nomenclature
  • Process Example
  • Recipe  & Physical Models
  • Linking Recipes to Equipment

Download Guide

S88 guide

Ray_Racine 150xx150

- Ray Racine

Senior Control Systems Engineer

White Paper: PLC5 to ControlLogix Conversions

“I have developed this white paper to provide you with a planning tool and some ideas that will help you to convert your Allen-Bradley PLC5 to ControlLogix. To date, I have been part of projects that have upgraded more than 80 PLC5 I/O racks on over a dozen processors. Through the course of these projects, we have learned how to execute the physical conversions and the PLC code conversions in a very effective manner. I’d like to share with you some of the lessons we’ve learned along the way that may assist you in your conversion. "

Download White Paper

“Michel and Julie did an outstanding job of transferring the existing, vintage Moore monitoring and controls over to the Modicon hardware. To do this work in a functioning control panel was no easy task and required a lot of thought and communication with our team. Nice work. Many thanks to all for your patience and diligence to this project!”


- Project Manager, Semiconductor Client

Manufacturing Intelligence

Manufacturing Intelligence (MI) enables you to see the trends and improve outcomes with the power that data brings. It helps to answer the important questions:

  • What is happening on your plant floor today?
  • How efficient is your equipment?
  • What are the reasons for production downtime and waste?
  • What reduces productivity and where can you make improvements?
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Control Panel Fabrication

Experience, industry knowledge and workmanship of our control panel design and build team is what sets us apart. Our ability to fabricate virtually any size control panel, from a junction box to massive multidoor panels, is what allows us to cater to your specific requirements and preferences.  We will work with you to address your range of needs, from design to installation.  Utilize our fabrication service for:

  • Junction boxes
  • OEM Panels
  • Drive Cabinets
  • Control Panels
  • Operation Stations
  • PLC Cabinets

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panel fabrication1

OT-IT Cybersecurity on pillar page

Cybersecurity & Operational Technology

We design safe, reliable and secure network solutions.  We are experts in Operational Technology (OT) and Information Technology (IT) and we speak the language of both the Factory Floor and Corporate IT. By taking each group’s priorities and objectives into consideration, we bridge the OT/IT gap.

A 3-step process to make your OT network and systems safe:

  1. OT/Cyber Audit
  2. Remediation
  3. On-going Monitoring & Support

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