MASK Control Systems - Bespoke Industrial Automation & Control Systems UK
Engineering Portfolio • Proven Field Reliability

Industrial Automation Projects &
Engineering Case Studies

Explore real-world automation projects including control panels, PLC systems, telemetry solutions, and custom machinery designed to improve efficiency, safety, and performance.

Discuss Your ProjectSpeak to an Engineer: +44 7412 999343
13+ Years
Engineering Heritage
100% FAT/SAT
Validated Sign-Off
Multi-Sector
UK & Global Cross-Discipline
3 Continents
Worldwide Deployment
Custom PLC Cabinet & HMI Integration by MASK Control Systems
BUILD SPECIFICATION:BS EN 61439 & CE/UKCA
VERIFICATION STATUS:100% TESTED & COMMISSIONED
CONTROL PLATFORMS:SIEMENS • MITSUBISHI • UNITRONICS
UK WORKSHOP: CULLOMPTON, DEVONEST. 2013
Trusted Across UK & International Industrial Projects:
UK Ministry of Defence partner with MASK Control Systems
Babcock International partner with MASK Control Systems
Field International partner with MASK Control Systems
Dunlop Aircraft Tyres partner with MASK Control Systems
Emirates partner with MASK Control Systems
Alstom partner with MASK Control Systems
Field-Proven Practical Engineering

Bespoke Automation Solutions Tailored to
Real Industrial Challenges

At MASK Control Systems, we design and deliver bespoke automation solutions tailored to real industrial challenges.

Our projects demonstrate our expertise in control systems, PLC cabinets, telemetry solutions, and custom-built machinery. Each solution is engineered to improve operational efficiency, enhance safety, and deliver reliable long-term performance.

From standalone control panels to fully integrated automation systems, we provide practical solutions that work in real production environments.

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99.8% Availability

High-reliability electrical componentry and clean PLC logic architecture designed for uninterrupted production duty cycles.

Zero-Defect FAT Testing

100% pre-commissioning simulation at our Devon workshop before shipping guarantees rapid, trouble-free on-site installation.

Direct Engineer Accountability

You collaborate directly with Adam and senior control engineers who design, wire, and commission your machinery.

Specialist Engineering Disciplines

Types of Solutions We Deliver

Across our projects, we specialise in comprehensive automation engineering capabilities tailored to diverse operational environments:

Electrical Control Panels

Custom-built, BS EN 61439 compliant enclosures engineered with premium switchgear, clean wire routing, and complete CAD documentation.

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PLC Automation Systems

Robust, deterministic control logic programmed on Siemens, Mitsubishi, Unitronics, and Rockwell platforms with structured code architecture.

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HMI Control Interfaces

Intuitive touch interfaces providing crystal-clear production metrics, diagnostic alarm logging, and multi-tier operator security access.

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Telemetry & Remote Monitoring Systems

Industrial cellular, radio, and cloud telemetry solutions for remote asset tracking, automated alarming, and predictive maintenance.

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Custom Machinery Automation

Specialist electro-mechanical integration for bespoke production lines, hydraulic/pneumatic feeds, automated augers, and test rigs.

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Safety-Critical Control Systems

EN ISO 13849-1 (PL e) and IEC 62061 (SIL 2/3) safety circuits, fail-safe interlocks, and emergency life-support monitoring architectures.

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Sector Versatility

Industries We Support

Our bespoke automation systems are engineered to withstand the rigorous standards, hygiene requirements, and safety compliance of diverse sectors:

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Food & FMCG

High-speed packaging, hygienic washdown control cabinets, pasteurization telemetry, and recipe dosing systems.

Manufacturing & Production

Tier 2/3 automotive supply lines, assembly automation, synchronized tooling, and robotics integration.

Marine & Offshore

Ruggedized, IP-rated deck machinery, ballast telemetry, navigation interlocks, and classification-approved panels.

Logistics & Material Handling

Conveyor diverters, sorting routing logic, automated guided vehicle (AGV) integration, and WMS connectivity.

Environmental & Safety Systems

Water treatment telemetry, hazardous refuge shelters, gas detection networks, and remote pumping stations.

Industrial Processing

Clean-room control cabinets, automated batch validation, chemical dosing, and pharmaceutical instrumentation.

Measurable Production Impact

Results Our Projects Deliver

Every project is engineered to achieve tangible operational metrics that justify capital investment from day one:

99.8%

Reduced Downtime

Deterministic logic, modular wiring, and proactive diagnostics eliminate intermittent line stoppages and nuisance trips.

VERIFIED PERFORMANCE
+35%

Improved Efficiency

Optimized VSD kinematic curves, synchronized feed cycles, and automated augers maximize throughput per shift.

VERIFIED PERFORMANCE
SIL 2/3

Enhanced Safety

Full compliance with Machinery Directive safety regulations protects machine operators and hazardous environments.

VERIFIED PERFORMANCE
-28%

Lower Operational Costs

Variable speed motor drives and intelligent energy management significantly cut electrical power consumption.

VERIFIED PERFORMANCE
100%

System Visibility

Real-time HMI graphical instrumentation and remote telemetry put instant operational status in the hands of engineers.

VERIFIED PERFORMANCE
15+ Yrs

Long-Term Reliability

Built with top-tier industrial components (Siemens, Schneider, Rittal) ensuring robust service lifespans and spare parts availability.

VERIFIED PERFORMANCE
The MASK Advantage

Why Our Projects Stand Out

Engineering integrity, technical transparency, and end-to-end accountability distinguish our automation projects from standard panel shops:

01

Fully Bespoke Engineering Solutions

Every panel, PLC program, and mechanical interface is custom engineered to solve your exact production bottlenecks, never forced into rigid off-the-shelf templates.

02

End-to-End Project Delivery

We take single-point responsibility across every stage: concept design, CAD schematics, in-house fabrication, programming, FAT, on-site commissioning, and lifecycle support.

03

Multidisciplinary In-House Team

Our combined electrical, software, pneumatic, and mechanical engineering expertise under one roof eliminates contractor friction and delays.

04

Seamless Integration with Existing Systems

We specialize in connecting legacy machinery, proprietary equipment, and multi-vendor fieldbus protocols into cohesive, modern plant networks.

05

UK-Based Engineering with Global Capability

Designed and built at our Cullompton, Devon engineering facility, with systems installed and operating across the UK, Europe, North America, and worldwide.

06

Proven Experience Across Multiple Industries

Over 13 years of cross-sector engineering success spanning food & FMCG, aerospace & defence, marine, utilities, and automotive supply chains.

Structured Delivery Model

Our Project Approach

We focus on delivering solutions that work reliably in real-world environments through a rigorous, five-stage engineering process:

01

Understand Your Operational Requirements

We perform a thorough engineering discovery: reviewing existing drawings, observing line cycles, identifying compliance obligations, and establishing exact performance KPIs.

STAGE 01
02

Design a Tailored Automation Solution

Our engineers produce detailed electrical CAD schematics, Functional Design Specifications (FDS), safety SIL/PL calculations, and Bill of Materials (BOM).

STAGE 02
03

Build and Test the System

Control panels are manufactured in-house to BS EN 61439 standards, followed by 100% Factory Acceptance Testing (FAT) with simulated I/O and client sign-off.

STAGE 03
04

Install and Commission

Our site engineers oversee mechanical mounting, cabling termination, live I/O verification, and formal Site Acceptance Testing (SAT) during planned production windows.

STAGE 04
05

Provide Ongoing Support

We supply complete As-Built documentation packages, operator training, remote telemetry monitoring, and rapid on-call technical breakdown assistance.

STAGE 05
Engineering Queries Answered

Frequently Asked Questions

Common questions clients ask when planning bespoke automation and control panel projects:

How long does a typical control panel or automation project take from order to delivery?
Project lead times depend on system complexity and component lead times. Standalone PLC panels typically take 4-8 weeks, while fully integrated automated lines or custom machinery rigs range from 8-16 weeks including full Factory Acceptance Testing (FAT).
Can you integrate with machinery or PLCs from manufacturers you didn't originally install?
Yes. A significant portion of our work involves retrofitting, modernizing, and interconnecting legacy production equipment from Siemens, Mitsubishi, Rockwell Allen-Bradley, Omron, and Unitronics with modern SCADA and fieldbus networks.
How do you verify and test custom control panels before site delivery?
Every system undergoes 100% point-to-point electrical continuity testing, safety loop verification, and complete simulation of PLC/HMI operating kinematics in our Cullompton facility prior to dispatch.
Do you provide Site Acceptance Testing (SAT) and commissioning abroad?
Yes. Our engineers travel worldwide to oversee mechanical installation, electrical interconnection, live SAT validation, and operator handover training across Europe, North America, and beyond.
What ongoing maintenance and warranty support do you provide post-commissioning?
All our control systems come with comprehensive warranty coverage, complete as-built electrical schematics, PLC software source files, and options for 24/7 emergency breakdown support and preventative maintenance contracts.
Turnkey Engineering Partnerships

Ready to Start Your
Automation Project?

Work with a UK-based engineering team delivering bespoke automation solutions worldwide. Discuss your technical specifications or schedule an on-site feasibility evaluation today.

Discuss Your ProjectSpeak to an Engineer: +44 7412 999343
BS EN 61439 Certified Workshop
100% In-House FAT Testing
Worldwide Commissioning & SAT
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