Engineering Discipline
Reliable Automation Logic Across Every Major Platform — From Standalone Machine to Plant-Wide SCADA
FERSMEK's software team programs PLC, SCADA, HMI, and robot systems across all major industrial automation platforms. We write code that runs reliably, is well-documented, and can be maintained and modified by your team or ours for years after commissioning.
What We Do
PLC programming is not just about making a machine run — it is about making it run reliably, safely, and in a way that operators and maintenance teams can understand without calling the programmer every time something goes wrong. FERSMEK's software engineers write automation code that is structured, documented, and tested to the same standard you would expect from a product release.
We work across four primary PLC platforms, three DCS platforms, and three major robot brands — handling everything from standalone machine controllers to plant-wide DCS and SCADA systems with historian, reporting, and ERP integration. For heavy industry clients in pulp and paper, metals, and chemicals, we engineer on Siemens PCS 7, Rockwell PlantPAx, and Valmet DNA — including migration from obsolete DCS platforms to modern architectures. Because our team includes both automation engineers and software developers, the gap between PLC logic and higher-level systems is a technical challenge we solve — not an interface issue we hand off to someone else.
Platform-Specific Expertise
We don't just know the platforms — we work on them daily. Each sub-page covers the specific capabilities, versions, and integration patterns we support.
Full Programming Capabilities
PLC Programming
Ladder, structured text, function block, and sequential function chart programming to IEC 61131-3 standards. All programs are structured for readability and maintainability — with consistent naming conventions, function block reuse, and inline documentation so your internal team or a future integrator can follow the logic without guesswork.
SCADA / HMI Development
Operator interfaces using Siemens WinCC, Rockwell FactoryTalk (Optix, View SE/ME), AVEVA Wonderware, and Ignition. Mobile-ready dashboards, alarm management, and historian configuration. For Rockwell environments, we deploy FactoryTalk Optix for cloud-capable HTML5 visualisation, FactoryTalk View SE for distributed multi-server SCADA, and ThinManager for centralised thin-client terminal management. We design screens for operator clarity — not maximum information density — so operators can understand machine state at a glance and fault-find without engineering support.
Robot Programming
Path programming, I/O integration, and safety zone configuration for Universal Robots, KUKA, and ABB robots. We handle full offline programming with simulation before on-site deployment to reduce commissioning time. Robot programs are documented and include parameter guides for adjusting speed, force, and paths without re-commissioning.
Safety PLC
Safety-rated logic programming for light curtains, safety mats, E-stop circuits, and two-hand controls to PLr/SIL requirements. We complete the full safety lifecycle — risk assessment, safety function specification, PLC programming, validation testing, and safety documentation package. CE marking support available.
DCS & Process Control
Distributed Control System engineering for continuous process industries. We work with Siemens PCS 7 and Rockwell PlantPAx for plant-wide process control — including migration from legacy DCS platforms (Honeywell TDC, ABB Advant, Bailey INFI 90) to modern architectures. DCS projects cover controller programming, operator station configuration, alarm rationalisation, and historian integration for industries where uptime and regulatory compliance are non-negotiable.
Motion Control
Multi-axis servo motion control, cam profiling, and electronic gearing for high-speed packaging and assembly applications. Experience with Siemens SIMOTION, Beckhoff NC/CNC, and Rockwell Kinetix servo platforms. For pulp and paper, metals processing, and converting industries, we deliver sectional drive control — coordinated multi-drive speed and draw/tension regulation across paper machines, winding lines, rolling mills, and printing presses. Sectional drive platforms include Siemens S120, ABB ACS880, Rockwell PowerFlex 755, and Danfoss (Vacon). Motion sequences are developed with simulation to verify trajectories and drive coordination before hardware installation.
Network & Communications
PROFINET, EtherNet/IP, EtherCAT, OPC-UA, and MQTT configuration for machine-to-machine and machine-to-MES communication. Network architecture design, managed switch configuration, and cybersecurity hardening for production network isolation. Full network documentation delivered with the project.
Robot Programming
FERSMEK programs industrial robots for welding, assembly, material handling, and machine tending applications. We handle robot selection, mechanical integration, safety zone configuration, and full offline programming with simulation before on-site deployment.
SCADA / HMI Platforms
Sectional Drive Platforms
DCS Platforms
Our Programming Process
Functional Spec
Define machine states, sequences, interlocks, alarm list, and HMI screen layout with client sign-off before a line of code is written.
Software Design
Program structure, function block library, data model, and SCADA tag list. Design reviewed before coding begins — changes at this stage are cheap.
Development & Simulation
PLC and HMI development with offline simulation and factory testing where possible. Robot paths developed with offline simulation tool.
FAT
Factory Acceptance Test against the functional specification. All sequences, alarms, and safety functions verified before shipping to site.
SAT & Handover
Site Acceptance Test with production parts. Full documentation handover — program backup, revision history, network diagrams, and operator manual.
Multi-Platform SCADA Integration — 3 PLC Brands on One Production Floor
A pulp and paper manufacturer with a mixed installed base of Siemens S7-1500, Rockwell CompactLogix, and Omron NX controllers needed a unified SCADA and OEE dashboard without replacing any existing PLC hardware. FERSMEK deployed Ignition as the SCADA layer, configured OPC-UA servers on all three PLC platforms, and developed standardised data models for production counting, downtime categorisation, and quality metrics. A single Ignition gateway aggregated data from all three brands into one historian and dashboard. The project was delivered in 10 weeks from functional specification sign-off to go-live.
Frequently Asked Questions
Related Services
Platform-Agnostic. Outcome-Focused.
We work with the platform you already have or help you choose the right one for your next project. Either way, you get well-structured, documented code that runs reliably.