Success Stories

Case Studies

Real-world examples of how Coded Controls has transformed automation systems for manufacturers across the UK.

Food & Beverage Packaging Line Modernization

Challenge: Legacy PLC system from 1998 was becoming unreliable, causing frequent production stoppages.

Solution: Complete system replacement with modern PLC/SCADA architecture while maintaining production continuity.

Results:

  • ↓ 85% reduction in downtime
  • ↑ 40% increase in production speed
  • ✓ Real-time monitoring and reporting
  • ⏱️ Zero production disruption during migration

Pharmaceutical Manufacturing Data Integration

Challenge: Multiple isolated systems with no data connectivity or visibility into production metrics.

Solution: Integrated data layer connecting all systems with custom dashboards and reporting tools.

Results:

  • ✓ Real-time production visibility
  • ↓ 30% reduction in quality issues
  • ↑ 25% improvement in OEE
  • 📊 Automated compliance reporting

Water Treatment Facility Automation

Challenge: Manual monitoring processes prone to errors and unable to meet regulatory requirements.

Solution: Custom SCADA system with automated monitoring, alerts, and compliance logging.

Results:

  • ✓ 100% regulatory compliance
  • ↓ 90% reduction in manual tasks
  • 🚨 Real-time alert system
  • 📋 Automated audit trails

Custom Control Panel Build for Packaging Automation

Challenge: Client needed a custom control panel to integrate legacy equipment with modern PLC systems.

Solution: Designed and built a complete custom control panel with integrated Siemens S7-1200 PLC, power distribution, and signal conditioning.

Results:

  • ✓ Seamless equipment integration
  • ⚡ Optimized power distribution
  • 🔧 Professional assembly and testing
  • 📋 Complete documentation and training

Automotive Parts Manufacturing Efficiency

Challenge: Multiple production lines with inconsistent performance and no centralized control.

Solution: Unified PLC/SCADA system with centralized monitoring and control across all lines.

Results:

  • ↑ 35% increase in throughput
  • ↓ 50% reduction in scrap rate
  • ✓ Predictive maintenance capabilities
  • 💰 12-month ROI achieved
50+

Projects Completed

Successful implementations across diverse industries

20+

Years Experience

Deep expertise in automation and control systems

98%

Client Satisfaction

Consistently delivering results that exceed expectations

0

Production Disruptions

Zero downtime during migrations and upgrades

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