Process Control
Stable, compliant production runs with clear HMIs, alarms and historian evidence for QA.
WHY PROCESS CONTROL MATTERS
From simple stop-start systems to tightly tuned loops that keep production steady.
Good process control is the difference between a line that "just runs" and a line that runs smoothly, consistently and efficiently. For simple applications, on/off control is perfectly adequate — start the conveyor, stop the conveyor, job done. But when speed, tension, temperature or flow need to stay inside a tight window, a more capable controller is essential.
That is where tuned PI or PID loops come in. By adjusting how quickly a loop reacts, how strongly it corrects and how it handles disturbances, we can turn an unstable process into one that behaves predictably.
SES Engineering helps sites choose the right level of control and tune it properly. Whether it is improving an existing loop or designing a new one, the goal is always the same: reduce waste, calm the process and give operators confidence.
We have delivered stable control on winding and slitting lines using drives and encoder feedback, improved tension systems on loss-in-weight feeders, and resolved pressure and flow oscillations in steam and utilities. Across all these systems, the winning formula is the same: good signals, clear logic and an HMI that shows exactly what the loop is doing.
Ready to steady your process?
If your loop hunts, overshoots or refuses to settle, a short review is often all it takes to understand what is going wrong. Get in touch and we will walk through your signals, controller settings and process behaviour to find the simplest path to stability.
What we deliver
- Loop tuning & optimisation – PI/PID setup and refinement to steady temperature, flow, pressure, tension and level loops without hunting or drift.
- Controller selection & migration – choosing and upgrading PLCs, drive controllers or stand-alone regulators to match the process and simplify future support.
- Interlocks & sequencing – robust state machines and permissives for conveyors, pumps, packaged skids and mode handling.
- Drive & feedback integration – coordinated variable-speed drives with encoders or load feedback for winding, slitting and speed-critical lines.
- Weighing & dosing control – loss-in-weight feeders, screw dosing and cut-off logic tuned for stable, accurate delivery.
- Utilities & process control – stable pressure, flow and temperature control for steam, gas and ancillary systems with clear alarm handling.
- Control philosophies & documentation – modes, setpoints, interlocks and cause-and-effect captured for maintenance and audits.
- SCADA/HMI visibility – operator screens, alarms and historian trends that explain loop behaviour and support quicker troubleshooting.
- Commissioning & support – bringing new or upgraded loops online safely and resolving issues quickly during start-up and handover.