INDUSTRIAL PROCESS

Industrial process engineering and automation solutions are the facility, utility, process, and control systems that improve production performance while reducing waste and safety risk. Hallam-ICS supports greenfield and retrofit projects by combining hands-on process understanding with engineering and controls to deliver practical, cost-effective improvements.

Industrial process facilities commonly include biomass & biofuels, chemicals & plastics, pulp & paper, building products, energy & power, steel & metals, cement, mining & minerals, and wood pellets. Hallam-ICS engineers support these environments with engineering, controls, safety, and compliance services tailored to the process and equipment.

Improvement typically starts with a process evaluation and optimization effort—capacity reviews, bottleneck identification, and options analysis—followed by engineered changes to equipment, utilities, controls, or material handling. Hallam-ICS takes a “boots on the ground” approach to find practical improvements that operators will actually use.

A process evaluation and bottleneck analysis reviews equipment capacity, constraints, and operating data to identify what’s limiting throughput or causing scrap/rework—then ranks improvement options by impact and cost. Hallam-ICS performs these assessments and turns them into actionable engineering and controls upgrades.

PLC + SCADA programming typically includes control system design, PLC/PAC/DCS programming, HMI/SCADA development, installation support, and startup/validation as needed. Hallam-ICS builds robust, reliable, and compliant control systems to improve uptime, safety, and operational visibility.

Yes. Many plants modernize controls through phased cutovers and staged commissioning to protect uptime. Hallam-ICS plans upgrades around production constraints so you can reduce downtime risk while improving reliability, safety, and maintainability.

OEE (Overall Equipment Effectiveness) measures availability, performance, and quality—helping teams pinpoint why a line isn’t producing at its true capacity. Hallam-ICS improves OEE by stabilizing sequences, improving alarm strategy, integrating data collection, and delivering dashboards that drive action.

An arc flash study analyzes electrical systems to quantify incident energy and define protective measures (labels, boundaries, PPE) for safer work. Hallam-ICS supports arc flash studies, mitigation, and safety training—especially important in continuous production facilities with complex power distribution.

Yes. Industrial electrical scopes often include low and medium voltage distribution (transformers, MCCs, switchgear, protective relaying), drives and controls, and substation SCADA/PLCs. Hallam-ICS designs and supports these systems to keep power reliable for machinery, automation, and critical controls.

A DHA identifies where combustible dust hazards exist and recommends safeguards to prevent dust fires, flash fires, and explosions. If combustible dust is present, specialized knowledge is needed to navigate codes/standards and interface with authorities and insurers. Hallam-ICS provides DHA, enhanced DHA services, mitigation, and dust collection system support.

It means starting with field walkdowns and operator input—walking down systems, understanding constraints, and validating how the process actually runs before recommending changes. Hallam-ICS uses this approach to deliver cost-effective solutions that don’t look good only on paper.

If you share your facility type, key constraints (throughput, waste, safety, downtime), and timeline, the Hallam-ICS team can recommend the right engineering, controls, and safety scope—then map a clear path to budget and schedule.