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Methodically replaced entire existing Foxboro DCS used to control 7 massive oven Lines for cookie manufacturing from raw material receipt to palletizing. New Rockwell FT View SE SCADA, Replaced PLC-5s for Logix PLCs keeping existing IO system and adding new and instruments. Built from scratch New Domain Controller, Redundant FT View SE Servers, library of recipes, FT Historian, Win911 over 12 Clients. Later years Upgraded FT View to newer versions, ultimately virtualized entire system.

Installed Automation Controls for Multiple Lines of massive Cookie Ovens, Dough Mixing, forming and cutting equipment, Packaging lines, conveyors, Sensors, pneumatic valves and Palletizers to produce and package varieties of cookies. Design included developing from scratch Multiple Networked PLCs, hundreds of VFD's, FT View Servers and clients, Multiple Panelviews in both English and Spanish. 

Brand New Pharma Mfg. Facility in VA, designed and installed a New Automation Controls Ethernet Network and running a VCenter controlled Virtual Server infrastructure including multiple Virtual servers for Domain Controller, SQL Server, 2 sets of Redundant FT View SE Servers, Historian, Win911, Asset Center, Multiple Thin Clients, 

Integrated Entire facility and Third-party equipment to the Facility wide SCADA. 

Complete Validation of Multi Virtual Networked Servers and Multi PLC and SCADA Systems

Developed all design documents, URS, DS, Schematics, validations protocols, as well as specified and purchase all hardware for Serialization in Italy and Spain plants. Performed physical installation and Integration of Multiple Ethernet Networked Optel Vision Systems a hardware Software translator between Rockwell System and Pallet Controlled by Siemans PLCs. Complete Integration into existing lines, some with robot palletizers. Validation of Multiple Networked PLC s and Optel Serialization

Integration of Multi Camera Systech Vision Systems for Serialization with a new Cognex based 360 Bottle Inspection system, for Case Serialization, Pallet Serialization system, Complete Integration into existing lines. Execute IQ, OQ and other Validation.

Developed and installed an entire   Batching system built on a Rockwell PLC System and IFix SCADA for the manufacture of Advil Tablets.  Integrated with existing and new equipment including and instrumentation. 

Designed a new electrical control and communications system based around a Rockwell Plc to replace the existing Dewyer DCT1000DC Dust Collector Controller and integrate VFD Controls with additional signals, alarms and New Ethernet and BACnet network connections to BMS System.

Designed, implemented VMWare virtual Servers, PLC Based BMS-Building Management system for management and control of all environmental air handling at a new facility. From Scratch New Domain Controller, Redundant FT View SE Servers, Historian, Win911. Multiple Clients. System was Developed completely remotely by team of three. 

Designed, built and programed Rockwell PLC and PanelView HMI, custom sorter, laner machine for Syringe products and integrated with robotic picker. Integrated with Systech Vision System for Serialization.  

Designed, built and programed custom Cognex based vision system to identify pallets by reading info on outside of cases as they enter pallet wrappers to automatically decide how pallets are to be processed.

Designed, built and validated the entire Automation Controls for entire Ultra-pure water (Distilled and WFI) manufacturing facility in Tampa. Automation Controls included Specify and Install Instrumentation and Valves as well as build from scratch a New Domain Controller, 2 sets of Redundant FT View SE Servers with hundreds of screens connected to multiple PLC's, Installed FT Viewpoint with multiple browsers, FT Historian, Win911, Multiple Thin Clients, Plantwide Ethernet Network with cellular m

Designed and installed an Ethernet networked Rockwell PLC and Red Lion HMI System to control a mobile contaminated water treatment site to return clean water to the Hudson River. Established a remote Ethernet connection and provide remote support to both PLC and HMI.

Upgraded the Chewing Gum base manufacturing control System and the wastewater treatment plant of the facility from outdated Square D and Modicon controls to Rockwell PLCs and SCADA Systems developed and installed by two separate groups. 

Replaced all existing non networked Allen Bradley Panelview 1200 and 1400s with fully Industial Ethernet Networked Rockwell RS View 32 systems and subsequently upgraded to FT View SE systems for all its cookie manufacturing plants across the US. 

+Vials, Bottles, Cartons, Cases, Pallets Forming, Filling, Conveying 

+Serialization: Barcode Label Printing, Vision Reading

+Vertical Coaters, Liquid and Powder Mixing 

+Syringe Filling, Pill Pressing, Coating, Blister Packing 

+Cookie Dough Ingredient Mixing, Forming, Baking, Packaging and Storage

+Candy and Gum base process

+Wastewater Treatment Plant Controls 

+Injection Molding and Extruder Controls and Operations

+Tubular Glass Cutting, Forming, Sealing 

+Developing Custom Test equipment

+ Debugging New or Existing Control Systems

+ Designing or Update Electrical Schematics, Documents 

+ Coding PLCs, HMIs or SCADA, 

+ Perform Software Backups

+ Design, Modify Manufacturing Network 

+ Inspection or Serialization Visions Systems Integration

+ Calibrating, Troubleshooting, Upgrading Analog Instruments 

+ Training Personnel

+ Providing Project Management