Automation & Embedded PLC
Solutions for
Machine Builders
Applied Controls empowers OEMs and machine manufacturers with intelligent PLC programming, control panel engineering, embedded systems, and industrial communication solutions. We design, develop, and deliver scalable automation systems that improve machine performance, reliability, and data visibility. From concept to commissioning, we partner with you to build future-ready industrial solutions.
Suggest
Clear direction before execution
Schematic
Engineering clarity
Develop
Precision in execution
Deploy
Seamless transition to production
HOW WE WORK
Structured execution. Clear responsibility. Reliable delivery.
We engineer automation systems with disciplined processes, defined ownership, and predictable outcomes minimizing risk across design, build, and commissioning.
Own the System
We deliver performance, safety, and reliability — beyond installation.
- Clear technical ownership
- Defined control architecture
- Compliance and safety focus
- Validation and testing discipline
Engineer with Focus
Lean teams. Senior oversight. No unnecessary complexity.
- Practical scoping and feasibility review
- Component standardization
- Reduced integration risk
- Efficient decision cycles
Build with Structure
Documented processes that ensure consistency.
- Electrical schematics and I/O documentation
- Defined milestones and review stages
- Factory Acceptance Testing (FAT)
- Change and revision control
Enable Continuity
Systems your team can operate and maintain confidently.
- Complete documentation and runbooks
- Knowledge transfer to plant engineers
- On-site commissioning support
- Ongoing service and lifecycle support
A focused automation partner for complex industrial systems.
For enterprise manufacturers and OEM groups expanding capacity or modernizing operations, We operates as a focused automation team delivering PLC panel manufacturing and embedded control solutions with sustained quality and consistency. We prioritize reliability, disciplined execution, and long-term ownership without disrupting existing operations.
How we fit
- Custom automation aligned to end-user requirements
- PLC panel manufacturing with consistent quality
- Integration with existing plant and control systems
- On-time delivery with predictable milestones
- Documentation for governance and internal handoff
- Enablement for in-house engineering and maintenance teams
Common enterprise engagements
- PLC panel manufacturing and system standardization
- Control system upgrades and modernization
- OEM machine automation support
- Embedded controller development
- Industrial communication and integration
- Long-term support and lifecycle maintenance
Our operating principles
- Sustained quality across products and services
- Lean, ethical, action-oriented execution
- Safe, secure, and structured work practices
- Continuous improvement of systems and processes
- Partnership-driven engagement with OEMs
Industrial automation engineered for reliability and scale.
Applied Controls delivers structured, standards-driven automation solutions for OEMs and enterprise manufacturers — from panel design to system integration and deployment.
Control Panels & Electrical Systems
- PLC-based control panel design and manufacturing
- AC drives, servo drives, and PC-based control integration
- UL / IEC compliant architecture
- Panel layout, wiring, and testing
PLC, SCADA & Integration
- PLC programming and HMI development
- SCADA design with OPC communication
- Custom data acquisition systems
- Integration with existing plant infrastructure
Instrumentation & Vision
- Process instrumentation and sensor integration
- Flow, pressure, temperature, torque, and load systems
- Vision inspection using smart and line-scan cameras
- Calibration and system validation
Automation & Motion Systems
- Pick-and-place automation (2-axis / 3-axis)
- Pneumatic, hydraulic, and servo motion systems
- Machine retrofitting and modernization
- Remote monitoring and industrial connectivity
Group of Companies
Applied Automation
A trusted partner in industrial automation, offering high-performance PLC, SCADA, and process control solutions for efficient and reliable operations.
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PTSS
Delivering end-to-end power and technical solutions with expertise in electrical engineering, power distribution, and reliable support services.
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Industrial Robotics
Advanced robotic systems for manufacturing, assembly, and material handling applications.
- High precision automation
- Collaborative robots (cobots)
- Custom end-effectors
- AI-powered vision systems
PLC Systems
Programmable Logic Controllers for reliable industrial process control and automation.
- Real-time monitoring
- Redundant systems
- Remote diagnostics
- Scalable architecture
SCADA Solutions
Supervisory Control and Data Acquisition systems for comprehensive process visualization.
- Intuitive dashboards
- Historical data analysis
- Alarm management
- Mobile accessibility
Motion Control
Precision motion control systems for complex automation applications.
- Servo & stepper motors
- Multi-axis coordination
- High-speed positioning
- Energy-efficient drives
Industrial Robotics
Advanced robotic solutions for modern manufacturing and automation
Overview
Our industrial robotics solutions deliver unmatched precision, flexibility, and reliability for demanding manufacturing environments. From high-speed assembly to complex material handling, our robots are engineered to enhance productivity while ensuring safety and quality.
Key Features
- 6-axis articulated robot arms with payload up to 500kg
- Collaborative robots (cobots) for human-robot interaction
- AI-powered vision systems for quality inspection
- Custom end-effectors for specific applications
- ISO/TS 15066 compliant safety systems
- Intuitive programming interface
Applications
- Automated assembly and pick-and-place
- Welding and material joining
- Machine tending and loading
- Palletizing and depalletizing
- Quality inspection and testing
- Packaging and labeling
Technical Specifications
- Repeatability: ±0.03mm
- Reach: 500mm to 3200mm
- Operating temperature: 0°C to 45°C
- Protection rating: IP54 / IP65 (optional)
- Programming: Teach pendant, offline software, ROS integration
PLC Systems
Reliable programmable logic controllers for industrial automation
Overview
Our PLC systems provide robust, reliable control solutions for industrial processes. Designed for harsh environments and critical applications, these controllers offer real-time performance, extensive I/O capabilities, and seamless integration with existing systems.
Key Features
- Modular architecture for scalability
- Hot-swappable I/O modules
- Redundant CPU configurations
- Built-in Ethernet and fieldbus connectivity
- IEC 61131-3 programming standards
- Integrated web server for diagnostics
Applications
- Process control and monitoring
- Machine automation
- Building management systems
- Water and wastewater treatment
- Energy management
- Batch processing
Technical Specifications
- Scan time: 0.1ms per 1000 instructions
- Memory: Up to 512MB program and data
- I/O capacity: Up to 8192 digital and 2048 analog points
- Operating temperature: -20°C to 60°C
- Communication: Ethernet, PROFINET, Modbus, CANopen
SCADA Solutions
Comprehensive supervisory control and data acquisition systems
Overview
Our SCADA solutions provide real-time visibility and control over industrial processes. With intuitive interfaces, powerful analytics, and robust security features, our systems help operators make informed decisions and optimize operations.
Key Features
- Customizable HMI with drag-and-drop designer
- Real-time and historical data trending
- Advanced alarm management with prioritization
- Mobile and web-based access
- Multi-language and multi-site support
- OPC UA/DA server and client
Applications
- Manufacturing execution systems (MES)
- Utility management (water, gas, electric)
- Oil and gas production
- Building automation
- Process optimization
- Asset performance management
Technical Specifications
- Tag capacity: Unlimited (license-based)
- Update rate: 100ms minimum
- Historical data: SQL database integration
- Supported protocols: OPC, Modbus, MQTT, REST API
- Platform: Windows Server, Linux
Motion Control
Precision motion control for demanding automation applications
Overview
Our motion control systems deliver precise, synchronized movement for complex automation tasks. From simple positioning to advanced multi-axis coordination, our drives and controllers provide the performance and flexibility needed for modern manufacturing.
Key Features
- Servo and stepper motor drives
- Multi-axis synchronization (up to 64 axes)
- Electronic gearing and camming
- High-speed position capture
- Energy regeneration and efficiency
- Safety-rated motion control (SIL 3)
Applications
- CNC machining and fabrication
- Printing and packaging
- Semiconductor manufacturing
- Textile and web handling
- Assembly and pick-and-place
- Material handling conveyors
Technical Specifications
- Position resolution: 24-bit encoder feedback
- Control loop: 62.5μs to 1ms
- Power range: 50W to 55kW
- Communication: EtherCAT, PROFINET, CANopen
- Motor types: AC servo, brushless DC, stepper
Precision in Automation
How we work: a structured path from strategy to deployment for reliable automation outcomes.
OIL AND GAS INDUSTRY
Automated tank farm system enabling safe oil collection, purification, storage, and redistribution through integrated PLC and SCADA control.
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Power & Distribution Industry
Integrated substation automation and data logging system delivering real-time monitoring, power analysis, and reliable control for efficient power distribution.
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Customized OEM Projects & SPM
SCADA-based common control panel enabling smart compressor monitoring, automated operation, vibration tracking, and seamless DCS communication.
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Textile Industry
Advanced textile data acquisition system delivering real-time production, power, and humidity monitoring for efficient spinning operations.
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Oil & Gas Industry
Tank Farm Automation - United Utilities, UK
Oil & Gas Industry
Tank Farm Automation for United utilities, UK is an project which Applied implemented for facilitation of a functioning of a tank farm. The operations of a tank farm is to collect oil from tankers and store into huge storage tanks used oil and dirty oil. The store Oil is then purified and transferred to a clean oil storage tank for re-distribution and tankers collect the same. The entire operation were implemented by Applied using a Rockwell Automation System - Compact Logic PLC over distributed IO and RSView Scada. Flowmeters, Pumps, Ac Drives, Thermocouples, Differential Pressure Sensors, Vacuum transducers, Pneumatic activated vales with feedback were integral part of this project.
Oil Regeneration
Tank Farm Automation for United utilities, UK is an project which Applied implemented for facilitation of a functioning of a tank farm. The operations of a tank farm is to collect oil from tankers and store into huge storage tanks used oil and dirty oil. The store Oil is then purified and transferred to a clean oil storage tank for re-distribution and tankers collect the same. The entire operation were implemented by Applied using a Rockwell Automation System - Compact Logic PLC over distributed IO and RSView Scada. Flowmeters, Pumps, Ac Drives, Thermocouples, Differential Pressure Sensors, Vacuum transducers, Pneumatic activated vales with feedback were integral part of this project.
Power & Distribution Industry
Substation Automation and Data Logging System
Substation Automation and Data Logging System (SADLS)
Substation Automation and Data Logging System (SADLS) is the foundation for all higher-level remote functions such as advanced power system management, automatically collecting, analyzing, alerting, reporting, and graphically representing the data while the equipment is in service.
Station-level systems are easy to use and adapt to customer-specific requirements, such as:
- Switch breaker connecting status
- Switch breaker rack In/Out status
- Live monitoring and historical trending of all alarms and events
- Power parameters like volts, amps, RMS, current RMS, frequency, kWh, etc.
- Power analysis like active, reactive, apparent power, and power factor
Customized OEM Projects & SPM
Other Industry Solutions including OEM Supplies
Common Control Panel for Air Compressor System
To Implement a SCADA controls system for a CCP To Monitor the Compressor utilization and switch OFF and ON the compressor based on plant requirement Time synchronization using Global positioning system To Communicate all information to DCS through RS485 Mod Bus/Ethernet TCP/IP Capture vibration Monitoring system parameters and communicate to DCS
Filter Press Automation
Filter press is a separation process, specially employed by solid/liquid separation using the principle of pressure drive, provided by a slurry pump. Filter press is a fixed volume and batch operation, The skeleton holds the filter pack together while pressure is being developed inside filter chamber. It consists of larger plates and frames filter presses with mechanical plate shifter. The function of the plate shifter is to move the plates and allow rapid discharge of the filter cakes accumulated in between the plates. The Process is fully automated and also manual operation feature has been provided.
Other Solutions which have become Standard Products
- Pick and Place 3 axis Robot for Plastic Injection Molding
- Dye stuff storage Automation for Dye selection in a Dyeing Plant
Control Systems for OEMs
- Control System for Yarn Conditioning Machine Yarn
- Loading Robot for a Yarn Mercersing Machine
- Control System for complete automation of Yarn Mercersing Machine
- Traverse Servo Motor Control for a Yarn Winding Machine
Other Industry - Machines Control Systems in Automotive Industry
- Heat Sealing Machine control system
- Automatic Tube Feed system
- Dunk Tank Leak Test System
- Speedometer Calibration system
- Fuel & Temperature Gauge Calibration system
- Radiator Cap Press system
- Radiator Crimping Press automation
- Inspection of Auto components using Vision Systems
- Control System Hydraulic Press for Heavy Engineering
- Industry Control System for functioning of Amusement Park
- Equipments Control Systems for Effluent treatment Plan
- Control System Hydraulic Press for Heavy Engineering
- Industry Control System for functioning of Amusement Park
- Equipments Control Systems for Effluent treatment Plan
Textile Industry
Advanced data acquisition and quality monitoring systems for spinning operations — from Blowrome to Ring Spinning and Looms
Data Acquisition System For Textiles — ProWin 2000
ProWin 2000 is a powerful Spinning Production, Power and RH Management Tool for departments from Blowrome to Ring Spinning and Looms. It offers a flexible solution to typical Production Management Problems. An impressive number of more than 200 installations of ProWin worldwide verify its reliability and performance.
ProWin 2000 acts as a front end to a back-end process deploying state-of-the-art PLCs and communication tools to realize a networked production management system. ProWin is built around industry-standard PLC control electronics and interfaces, making it the most reliable networked monitoring system in the world for this application. The open architecture of ProWin is further evident in the wide range of machinery support and flexibility in configuring fault inputs.
Quality Monitoring System
The uniformity of yarn/sliver along the length is monitored by this system. The system receives inputs from the user through the HMI, and deviation parameters are displayed on the HMI in real time. The user can monitor the yarn across 4 different lengths simultaneously, with the following key metrics displayed:
- CV% (Coefficient of Variation)
- U% (Unevenness Percentage)
- Number of Thin Places per km
- Number of Thick Places per km
- Number of Nep Places per km
Advanced Monitoring Capabilities
The Quality Monitoring System is engineered for high-speed textile applications. Material can be monitored for up to 4 different sample lengths simultaneously. Sampling resolution can be as close as approximately 10 mm even at material speeds of around 600 m/min.
The monitored values are calculated continuously online using a sliding window of the specified length. If the speed of the material falls below 1 m/min, the monitoring process pauses automatically and resumes only when the speed exceeds 1 m/min — ensuring accurate and reliable data at all production states.
Let's talk about what you're building.
If you're exploring industrial automation or need expert technical support, reach out to us for consultation and assistance.
Head Office
Applied Automation Systems Private Limited
- Address S.F, 415, Codissa Road, Peelamedu, Sivasakthi Nagar, Coimbatore, Tamil Nadu 641004
- Contact +91 91500 66488 | +91 9487593083
- Email sales@aaspl.net | service@aaspl.net
- GST Number 33AADCP2476R1ZW
Factory
Applied Control Equipment Systems
- Address 3B, Athappangounden Pudur to Ravathur Road, Irugur, Coimbatore – 641103
- Contact +91 8111 000 656 | +91 9487593083
- Email sales@aaspl.net | service@aaspl.net
- GST Number 33AAEFA4200C1ZH
Business Schedule
Working Days & Timings:
Monday to Friday (8:30 AM – 6:00 PM)