Industrial Automation Solutions & PLC Systems
Advanced automation engineering, PLC programming, and control systems designed to improve efficiency, reduce downtime, and optimize manufacturing operations worldwide.
Advanced Industrial Automation Tailored to Modern Production
At MASK Control Systems, we provide advanced industrial automation solutions tailored to modern manufacturing environments.
From PLC programming and HMI development to complete automation system design and integration, we deliver reliable, scalable solutions that improve production efficiency and operational control. As a UK-based automation engineering company with global capability, we support manufacturers across multiple industries with custom-built automation systems and control technologies.
What is Industrial Automation?
Industrial automation involves the use of control systems, software, and machinery to automate production processes, reduce manual intervention, and improve consistency.
By implementing automation systems, manufacturers can increase output, enhance product quality, and gain greater visibility over operations.
Our Automation Capabilities
From discrete logic programming to fully integrated factory-wide control architectures.
PLC Programming
We develop custom PLC programs tailored to your machinery, processes, and operational requirements adhering to IEC 61131-3 standards.
HMI Development
User-friendly HMI touch interfaces designed to provide clear system control, live diagnostics, alarm logging, and intuitive operator interaction.
Control System Engineering
Design and implementation of complete automation control systems, electrical cabinets, safety relays, and instrumentation.
Automation System Integration
Connecting standalone machines, PLCs, robotics, sensors, and ERP/MES databases into a unified, efficient workflow.
Legacy System Upgrades
Modernising outdated and obsolete PLC hardware (e.g. Siemens S5 to S7-1500, legacy Mitsubishi, Omron, Allen-Bradley) with drop-in replacements, updated wiring schematics, and zero loss of machine functionality.
PLC System Expertise
We work across all leading PLC platforms to deliver reliable, scalable automation systems tailored to your specific plant preferences:
Automation Solutions We Deliver
Our solutions are designed to improve efficiency, reduce errors, and support scalable operations:
Machine Automation
Standalone custom machine control, pneumatic actuator coordination, servo axis positioning, and safety interlock integration.
Production Line Automation
Synchronised conveyor networks, automated buffer stations, high-speed routing, and robotic palletising lines.
Process Automation
Precision batch mixing, temperature PID control, dosing pumps, valve manifolds, and CIP (clean-in-place) sequences.
Control System Design
Hardware specification, electrical schematics, motor control centers (MCC), and SIL/PLe functional safety compliance.
Data & System Integration
Connecting field devices to supervisory SCADA and factory database systems via Modbus, Profinet, and Ethernet/IP protocols.
Smart Monitoring & Automation
Cloud-connected IIoT telemetry, real-time performance tracking, predictive fault alerts, and secure remote support dial-in.
Problems We Solve
We eliminate common factory vulnerabilities and transform inefficient operations into reliable assets:
Manual & Inefficient Processes
We automate repetitive, labour-heavy tasks to accelerate throughput and ensure consistent cycle times.
Production Downtime
Reliable industrial automation systems and robust electrical hardware reduce unexpected stoppages.
Lack of System Integration
We connect fragmented standalone machinery into unified, transparent communications loops.
Inconsistent Product Quality
Automation guarantees exact repeatable tolerances, reducing scrap rates and defect variance.
Outdated Control Systems
We upgrade obsolete, unsupportable PLC platforms before component failure causes catastrophic downtime.
Benefits of Industrial Automation
Automation is not just about replacing labour—it builds scalable operational resilience:
Increased Production Efficiency
Higher line speeds, shorter cycle times, and predictable manufacturing output around the clock.
Reduced Labour Dependency
Lower recurring overheads and freedom from staffing shortages on hazardous or repetitive operations.
Improved Product Quality & Consistency
Automated sensor verification and deterministic control eliminate human error from critical assembly steps.
Greater Operational Control
Touchscreen parameter adjustments, batch recipe management, and password-protected operator roles.
Real-Time System Visibility
Live telemetry, OEE metrics, and predictive warning alerts sent directly to smartphones and cloud portals.
Scalable Manufacturing Processes
Modular automation architectures designed to expand smoothly as customer order volumes grow.
Industries We Serve
We deliver automation solutions across a wide range of industries, tailored to exact regulatory standards:
Food & FMCG Automation
Hygienic washdown, packaging, batching, and high-speed sorting.
Aerospace & Defence
High-precision testing rigs, safety interlocks, and traceability.
Pharmaceutical & Medical
Cleanroom automation, validation documentation, and precision dosage.
Marine Automation Systems
Offshore control panels, saltwater-resistant telemetry, and vessel power.
Automotive (Tier 2/3)
Robot cell integration, automated assembly, and press monitoring.
Logistics & Warehousing
Conveyor control, automated sorting, AGV integration, and palletising.
Our Automation Process
A structured 6-stage engineering delivery process ensuring on-time deployment and operational success:
Requirement Analysis
Understanding your production process, cycle times, safety requirements, and automation targets.
System Design
Developing tailored automation solutions, electrical schematics, network topology, and control architecture.
Programming & Development
PLC logic programming, HMI screen design, safety zone configuration, and communication setup.
Integration
Connecting mechanical equipment, actuators, sensors, and central supervisory systems into a unified workflow.
Testing & Commissioning
Rigorous FAT and SAT testing, safety interlock verification, line tuning, and operator handover.
Ongoing Support
Continuous preventative maintenance, telemetry monitoring, remote diagnostics, and SLA breakdown response.
Why Choose MASK Control Systems
We deliver automation solutions that improve performance, reliability, and long-term operational success:
Expertise in PLC & Automation Systems
Over 13 years of proven engineering experience delivering advanced automated systems for high-throughput production lines.
Custom-Built Engineering Solutions
No off-the-shelf compromises. Every machinery mechanism and control rung is tailored to your exact manufacturing requirements.
Multidisciplinary Engineering Team
In-house mechanical, electrical, and software engineers working seamlessly together under one single engineering management umbrella.
UK-Based with Global Delivery
Headquartered in Devon, UK, supporting commissioning, system installations, and field projects across the UK, Europe, and the Middle East.
Reliable, Scalable Automation Systems
Built with Tier-1 industrial-grade hardware, comprehensive fault diagnostic routines, and modular expansion capacity.
Long-Term Technical Support
From emergency field breakdown response to cloud telemetry monitoring and preventative maintenance SLAs, we protect your investment.
Ready to Improve Your Production Systems?
Work with a UK-based automation engineering team trusted by manufacturers worldwide.