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Developments in IIoT devices are presenting Process Solutions with exciting new possibilities for providing lower cost data acquisition tools and services to end-users. Many of the industry’s leading control component manufacturers are offering more cost-effective devices that communicate using web communication protocols such as RESTful, which is a software architectural style for distributed hypermedia systems, and MQTT, which is an ISO standard publish-subscribe-based messaging protocol. These communication protocols enable Process Solutions to communicate to devices operating in the field using a host of programming languages.

The ability to directly communicate with devices in the field not only allows Process Solutions to quickly and easily provide remote service but also gives the ability to integrate with data collection and analytics software such as our new DAQuery™ software systems. Through DAQuery™, Process Solutions can create custom dashboards, which clearly and accurately display real-time and historical production data. By utilizing their production data, manufacturers can discover new ways to increase production output, reduce waste, save on operational costs, and seamlessly distribute necessary information directly to workers via HMI displays, tablets, TVs or other mediums.
Examples of new IIOT devices currently being offered by leading control components manufacturers include remote ethernet switches that collect data from field sensors and send that information directly to databases or live screens using HTTP requests, RESTful, or MQTT protocols.  Numerous smart sensors are being developed and entering the market with these protocols, which allows seamless machine to machine data collection and communication to databases.  These smart sensors can provide manufacturers who don’t need PLC-based controls, the ability to harvest information from their manufacturing environment. Some switches even have EDS files, so they can also serve as remote-IO replacements for a fraction of the cost.

Another example of cost-effective IIoT devices on the market today are IIoT gateways. These devices function similar to a microcontroller, except they have been re-engineered into a hardy, industrial UL rated device that can accept field IO.  One possibility is to use IIoT gateway devices as a lower cost OPC-UA or OPC-DA server to log data to a database from PLCs. OPC-UA or UPC-DA is a machine to machine communication protocol for industrial automation focused on communicating with industrial equipment and systems for data collection. Traditionally, Process Solutions would purchase an industrial PC to run these data collection servers; however, industrial PCs have been rising in cost, power requirements, and panel space.  These cost-effective IIoT gateway devices can run on free, low-overhead operating systems such as Linux, instead of having to purchase Windows operating systems and dealing with time-consuming Windows updates.  Another advantage of IIot gateways is the ability to be used as a remote access point. With consent from the client, this remote access allows Process Solutions to view the client’s I/O from our offices and help troubleshoot their systems, even if the client doesn’t have a PLC.  For smaller applications, IIoT gateways devices can also serve as a PLC replacement due to the ability to access system code and remote IO.

These are just a few ways that IIoT devices such as switches and IIoT gateways are improving the way manufacturers and integrators interact with industrial equipment and run their overall production. Process Solutions team of Data Science engineers are experts in integrating IIoT technologies into both new and existing systems. Visit www.processsolutions.com to get in touch with an engineer and learn how you can begin improving your production process with IIoT devices and DAQuery™ software systems.

Located near Seattle Washington, Process Solutions is the Northwest’s largest control systems integrator. With 30+ years in business and over 100 engineers and technicians on staff, Process Solutions has the knowledge, experience, and capacity to take on almost any automation project. Process Solutions provides a wide range of automation services, including electrical control panels, PLC and HMI programming, Industrial and collaborative robots, energy management and refrigeration systems, SCADA, and data science and analytics. For more information, please visit www.processsolutions.com.

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Vaclav Mydlil
Sr. Director of Advanced Automation
Vaclav leads the dynamic Energy Management and Refrigeration Division at Process Solutions. With an impressive 20 years of experience in power demand management and refrigeration control systems, Vaclav is the driving force behind one of the company’s most innovative systems.

His expertise extends to PLC and cloud-based systems, ensuring seamless integration and optimal performance. Vaclav’s commitment to excellence is underscored by his Master of Science degree, specializing in control systems and electrical engineering, which he earned from the University of Life Sciences in Prague, Czech Republic.

Beyond the office, Vaclav’s passions include kayaking, snow skiing, and woodworking. Most of all, he enjoys moments spent with his wife and three kids.
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Steve Pelton
Vice President of Sales
With over 20 years at Process Solutions, Steve Pelton has held various roles, including Sales Engineer, Sales Director, and his current position as Vice President of Sales.

In addition, Steve oversees Process Solutions’ Energy Management and Refrigeration Division — ensuring the company remains at the forefront of energy-efficient solutions that cater to diverse food production applications. Steve also spearheads the strategic development of the company’s machine monitoring solutions, aligning them with client needs and market trends.

Steve’s background includes mechanical engineering, but his career trajectory has mainly focused on control systems marketing and management. His ability to bridge technical expertise with business acumen has been instrumental in Process Solutions’ growth.

Outside the office, Steve passions include conquering rugged trails on his mountain bike, perfecting his golf swing, and exploring new destinations with his family.
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Matt Barnes
Chief Financial Officer
Matt, with 28 years of financial strategy and accounting experience, plays a pivotal role at Process Solutions. As the Chief Financial Officer (CFO), he spearheads the company’s growth strategy, ensuring financial stability and health.

Beyond traditional financial management, Matt also oversees strategic initiatives aimed at optimizing Process Solutions’ on-hand inventory costs and availability. By fine-tuning inventory management, Matt ensures the company can meet client needs efficiently and maintain a healthy bottom line.

Matt graduated with a degree in accounting from Western Washington University and previously served as a financial executive at a large retail corporation. Outside of work, Matt enjoys traveling, soccer and spending time with his family.
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Kevin Orr
Executive Vice President
Kevin boasts an impressive tenure of over 25 years at Process Solutions. His position in the company has been multifaceted, spanning roles as a project engineer, engineering manager, and Process Solutions’ first Executive Vice President.

Under Kevin’s leadership, the food processing division has flourished, earning its reputation as of the most respected in the industry. Today, Kevin closely collaborates with executives from leading food processors and food processing equipment manufacturers across the country.

Kevin is a devoted husband and father with a passion for international travel.
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Todd Busby
Chief Executive Officer
Todd has dedicated over 30 years to Process Solutions, where he has worn multiple hats—from panel builder to project engineer and sales representative.

As the CEO of Process Solutions, Todd has spearheaded significant transformations. Under his leadership, the company has diversified into new industries, acquired a world-class facility, and more than doubled its size.

Todd, a native of the Puget Sound region, is a devoted husband, father, and avid outdoorsman. When he’s not at work, you’ll find him supporting his three kids in all their pursuits or hunting and fishing in Eastern Washington.
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David Crumpley
President
David has dedicated over 15 years to Process Solutions, where he has served as a Senior Engineer, Vice President, and now Chief Operating Officer. His multifaceted experience spans technical expertise, strategic leadership, and operational efficiency.

As the head of Process Solutions’ Water/Wastewater division, David orchestrated the modernization of the company’s internal systems and boosted operational efficiency across the organization.

In his current role as President, David continues to drive innovative initiatives aimed at expanding the company’s reach and further streamlining internal processes.

Outside of work, David enjoys spending quality time with his family and pursuing his passions as an avid outdoorsman.
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Service

We provide numerous remote and on-site services to our customers, including software upgrades, troubleshooting, hardware replacement, and feature additions. Our staff size provides us flexibility to quickly respond to standard time frames and emergency service.
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Services

Commission

Process Solutions provides commissioning services, as well as system start-ups. Our staff will travel anywhere in the world to help you get your system up and running. We start up hundreds of systems per year, and our licensed electricians on staff can pull permits as needed.
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Our Engineering and CAD department can create a wide range of documents, including functional specifications, software design documents, test manuals, O&M manuals, P&ID, system drawings, and network drawings. Drawings for FDA level documents are a particular specialty.
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Code

Process Solutions software designers are equipped to handle any size job. We structure our program code to be easily read by both customers and engineers, making support and system upgrades fast and easy.
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Build

Process Solutions builds over 3,000 panels per year. Our high-volume model makes our technicians experts in the field and provides our customers with an industry leading experience. Efficient manufacturing practices, mixed with automated manufacturing equipment, allows for quick and consistent job completion.
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Design

Creation of custom designs for new and legacy systems. All drawings are template based using automatic CAD macros. Our techniques create an efficient design process with recognizable and easy to understand drawings.
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