System overviewEngineered around your production requirement
ES-PRO delivers comprehensive PLC, HMI, and SCADA modernization solutions for existing electroplating, anodizing, chemical cleaning, and surface treatment lines. Our upgrade services help manufacturers replace outdated control systems, improve process visibility, and enhance production reliability without requiring complete equipment replacement.
Our solutions cover PLC hardware and software upgrades, HMI interface redesign, SCADA system development, industrial communication integration, and SQL-based production data management. Key functions include automatic process control, recipe management, real-time equipment monitoring, alarm and event logging, production reporting, and historical data analysis.
Each upgrade is carefully planned around the existing machine configuration, operating sequences, and production requirements. ES-PRO focuses on maintaining essential machine functions, ensuring compatibility with existing field devices, and minimizing production interruptions during system migration.
With integrated automation and data management capabilities, our solutions provide greater process transparency, improved troubleshooting efficiency, reliable production traceability, and a scalable platform for future manufacturing expansion.
Typical process architectureProcess flow
Existing Control System AssessmentPLC, HMI & SCADA Upgrade PlanningHardware & Software SelectionElectrical & Communication System DesignPLC Programming & HMI DevelopmentSCADA Integration & Database ConfigurationEquipment Communication TestingFactory Acceptance Testing (FAT)On-Site Installation & System MigrationTesting & CommissioningOperator Training & Technical Documentation
The displayed flow is an engineering reference. The final sequence, chemistry, dwell time and control points are confirmed for the customer’s process.
ApplicationsWhere this system fits
ES-PRO PLC, HMI and SCADA Upgrade solutions are designed for existing surface treatment lines requiring improved automation, process monitoring, production management, and system reliability.
Electroplating Lines: Upgrade automatic process control, rectifier communication, plating recipe management, and production monitoring systems.
Anodizing Lines: Improve temperature control, rectifier integration, current and voltage monitoring, process sequencing, and historical data recording.
Chemical Cleaning & Stripping Lines: Modernize chemical treatment controls, tank temperature monitoring, dosing systems, and process timers.
Automatic Gantry Hoist Systems: Upgrade PLC motion control, hoist positioning, automatic transfer sequences, collision prevention, and safety interlocks.
Water Treatment & Wastewater Systems: Integrate pump controls, tank-level monitoring, conductivity and pH measurements, chemical dosing, and alarm management.
Existing HMI Modernization: Replace outdated operator panels with modern touchscreen interfaces featuring multilingual displays, recipe management, and equipment diagnostics.
SCADA & Production Data Management: Implement centralized monitoring, SQL database integration, production reporting, alarm history, user access control, and process traceability.
Legacy Control System Replacement: Migrate obsolete PLC hardware and software to modern platforms while maintaining essential machine functions and compatibility with existing equipment.
