Bespoke Control Systems Design, PLC Programming & Control Panel Build
Features
- Bespoke control systems design to site standards
- Control engineering: requirements, control philosophy and documentation
- PLC control system design & PLC programming (Siemens / Allen-Bradley)
- Control panel design and build (PLC, MCC and pneumatic panels)
- FAT/SAT support, installation and commissioning
- HMI design for clear operator workflow (where required)
- Integration with ERP/MRP systems (e.g., SAP) where required
- Hazardous area / ATEX panel design (where applicable)
Key Benefits
- Reduced downtime through robust, maintainable automation
- Consistent operation across shifts and sites
- Faster fault-finding with structured design and documentation
- Scalable control architecture for future expansion
- Improved safety and compliance through engineered interlocks
- Lower lifecycle cost through standardisation and supportability
Bespoke control systems and control engineering
Practicon designs and delivers bespoke control systems for industrial automation—covering control engineering, PLC control systems, panel build, integration and commissioning.
Bespoke control systems are engineered around your equipment, process constraints, site standards and future expansion plans. Practicon provides end-to-end control engineering—from requirements capture and control philosophy through design, build, testing and commissioning—so your automation performs reliably in production, not just on paper.
We focus on delivering practical, maintainable industrial automation and control systems that improve uptime, consistency and operator confidence. Whether you’re upgrading legacy controls, integrating new equipment, or standardising control panels across a site, we design solutions that are safe, scalable and easy to support long term.
Best-fit for: plant upgrades, new process lines, OEM integration, retrofits, and multi-vendor automation projects.
- Requirements capture, site surveys and I/O definition
- Control philosophy / functional specification (where required)
- Electrical design and control panel design to site standards
- PLC programming, testing and commissioning
- Documentation and handover
Bespoke PLC Control System Solutions
Our team of engineers have considerable experience of Siemens S7-400, S7-300, S7-1500 & S7-1200 PLC’s and Allen Bradley Control Logix, Compact Logix and Micro Logix PLC’s as well as HMI (Human Machine Interface) and SCADA (Supervisory Control and Data Acquisition) solutions across many industrial sectors. Our applications range from simple single weigher systems to data monitoring and capture system, from continuous real time process and general plant automation solutions.
PLC control system design, programming and commissioning
A reliable PLC control system starts with robust design and disciplined commissioning. We deliver PLC programming and configuration for new machines and plant upgrades, ensuring deterministic control, clear operator feedback, and maintainable code structures aligned to your standards. Our engineers support the full lifecycle—from I/O definition and simulation/testing through installation support, I/O checkout and commissioning—so you achieve predictable start-up and stable operation.
- PLC programming and configuration
- I/O definition, addressing and signal testing
- Logic simulation / pre-commissioning support
- On-site I/O checkout, commissioning and tuning
- Legacy PLC upgrades upgrades/retrofits and migration planning
Control panel design and build (PLC, MCC and pneumatic panels)
We have the engineering capability to design and build PLC and MCC (Motor Control Centre) control panels including pneumatic controls for all types of different environments, including Hazardous ATEX Zone 1 & 2 for gas and ATEX Zone 21 & 22 for dust. Control panel layouts and schematic wiring diagrams are designed using AutoCAD for customer approval prior to commencement of manufacture.
- Control panel design (layout + schematics)
- Control panel build and FAT testing
- MCC and motor control integration
- Panel modifications and upgrades
- Spares strategy and future expansion allowances
All of our products and bespoke control panels are manufactured to the highest standards using quality components and organised logically allowing for future expansion. See our panel building workshop facility for build capability and quality control.
See more details about Bespoke Control Systems Design, PLC Programming & Control Panel Build
HMI design and operator interfaces
Human Machine Interface terminals (HMI) can also be a vital part of most control systems and more importantly, the visual aspect of the system needs to be concise and user-friendly as well as functionally diverse for the customer’s needs. For plant-wide supervisory monitoring, alarms, trends and reporting, see our SCADA Systems & PLC Control Systems solutions.
- Operator workflow and screen navigation
- Alarms, prompts, and guided steps (where relevant)
- Maintainable screen standards and templates
Integration with ERP/MRP systems
With our broad knowledge of supplying process control systems and integration with ERP (Enterprise Resource Planning) & MRP (Material Resource Planning) system including SAP, JD Edwards & Prism systems we are able to provide the full spectrum of services.
- Material/production data exchange
- Reporting and traceability support
- Reducing manual re-entry
Typical industrial automation applications
Our bespoke automation solutions support a wide range of industrial processes, including:
- Weighing and batching control systems (loss-in-weight, gain-in-weight, recipe-driven operations)
- Batch control system for recipe batch blending (automation for mixing, dosing and sequencing
- Tank farm automation (transfer control, level/flow monitoring, valve manifolds)
- Recipe dispensary weighing for controlled handweigh dispensing (guided operator steps, verification, traceability)
- Machine upgrades and panel replacements (legacy modernisation, standardisation)
- Data capture and reporting (alarms/events, trends, production records)
- Utilities and ancillary systems (pumps, heating/cooling loops, CIP where applicable)
Each application is engineered for reliability, maintainability, and safe operation—designed to meet production throughput and compliance requirements.
How we deliver bespoke control systems
- Requirements capture and site survey
- Control philosophy / functional description (as applicable)
- Electrical design + panel layouts
- Build, test, install and commissioning
- Documentation and handover support
Typical project deliverables
- Schematics, wiring diagrams, and panel layout drawings
- IO lists and commissioning check sheets
- Test documentation (FAT/SAT where applicable)
- Operating and maintenance documentation (where applicable)
FAQs
What is a bespoke control system?
A bespoke control system is an engineered automation solution designed around your process, equipment and operational constraints. It typically includes control engineering, PLC control systems, control panels, operator interfaces and commissioning to deliver reliable, repeatable operation.
What does a control systems engineering company deliver?
Typical deliverables include requirements definition, electrical design, control panel design/build, PLC programming, HMI interfaces, testing, installation support and commissioning—plus documentation for long-term maintenance.
What is included in control panel design and build?
Control panel design and build usually covers electrical schematics, panel layout, component selection, wiring, testing and quality checks. Panels can be designed to allow future expansion and safe maintenance access.
Can you build PLC and MCC control panels?
Yes—projects often include PLC control panels and MCC (motor control centre) panels, depending on the process requirements and site standards.
Do you support hazardous area control panels (ATEX)?
Where required, control panels can be designed and built for hazardous environments, including ATEX zones for gas and dust applications.
Which PLC platforms do you work with?
Bespoke PLC control system solutions often include Siemens S7 and Allen-Bradley platform families, depending on customer standards and existing installed base.
What’s the difference between PLC and SCADA?
A PLC controls machine/process logic in real time. SCADA provides supervisory monitoring, alarms, trends and reporting across multiple PLCs and assets.
How do I specify the right control engineering solution?
Start with your process description, IO count, safety/environment needs, operator workflow requirements, integration requirements (ERP/MRP), and commissioning constraints. An engineer can then recommend the most practical architecture and delivery approach.
Request a Quote
Request a quote to discuss your process, tag count, alarm strategy, reporting requirements for a Bespoke Control Systems. We’ll advise the best-fit approach for your plant and budget.
If you have any questions or would like further information about Bespoke Control Systems Design Solutions, please contact us.
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