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PLC & HMI programming

Process Solutions develops complete PLC control system services, including PLC and HMI programming, control panel fabrication, system migration, PLC integration, and support.

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PLC Control System

PLC Control Systems

Solutions for streamlined process control

We develop PLC systems that improve process control, boost efficiency, and maximize production. Our engineers have hundreds of combined years of experience working with industry-leading PLC platforms, including Rockwell, Siemens, and Schneider Electric.

Our PLC programs are developed with modular code blocks that reduce development time and have been thoroughly field-tested for reliability and performance. Our modular approach also simplifies the process for making program modifications, allowing for easier expansions or system upgrades.

IEC 61131-3 Compliance

Our team of engineers are proficient in IEC 61131-3 standards for PLC programming.

Modular Code Blocks

We minimize development time through the use of modular code blocks with proven reliability and performance.

UL 508A Panel Shop

Specializing in the design and build of custom PLC control panels and HMI panels.

programming methods

Flexibility for the future

Process Solutions can employ a variety of programming methods depending on the intended application and the overall goals of our clients. Each of our PLC programs adhere to IEC 61131-3 standards and can utilize modular code blocks for quicker development time and greater flexibility for future modifications and expansion efforts.
  • Ladder Logic
  • Function Block Diagram
  • Structured Text
  • Instruction List
  • Sequential Flow Charts
PLC-5 Controls Platform

PLC migration and upgrades

Modernizing the way things get done

As legacy PLC-5 control systems and other PLC models continue to age, finding replacement parts is becoming more difficult and system maintenance costs are rapidly increasing. Migrating to a modern PLC platform offers significant improvements to overall equipment effectiveness (OEE), system reliability, parts availability, support, and process efficiency.

When performing PLC upgrade services, we do our best to reduce downtime and costs by developing a thorough migration strategy using either a phased or total replacement approach. We also work to maintain the existing field wiring and enclosure footprint whenever possible.

In addition, our PLC migration services include updating all system schematics, converting existing logic and programs to the new PLC platform, and rigorous testing to ensure proper operation and compatibility.

PLC control panel manufacturing

High-performance hardware

Process Solutions is a UL-certified panel shop specializing in manufacturing high-performance PLC control panels designed to your required specifications.

In addition to manufacturing, our capabilities include integrating PLCs with new or existing equipment and systems, including HMIs, SCADA systems, machine monitoring systems, and MES systems.

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Panel Example 1
Drive Panel Example
Stacklight Panel Example
Panel Example 7
Panel Example 6
Panel Example 5
Panel Example 3
Panel Example 4
Panel Example 2
GE PLC Panel
VFD Panel Example 2
HMI Enclosure Interior Example
PLC Example Two
PLC Panel 2-door Example
Sloped Enclosure Example
Stainless Steel PLC Panel Example
Three Door VFD control panel with remote I/O and a disconnect switch
Two Door Panel Example
Two-door VFD Control Panel in stainless steel enclosure
Custom Control Panel with Servo Drives Installed
Custom PLC Control Panel Built by Process Solutions
Industrial Control Panel With and IO rack and Stainless Steel Enclosure
Custom Control Panel Builder
Electrical Control Panel in Stainless Steel Enclosure
VFD control panel with yellow terminal wiring
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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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Services

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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Services

Document

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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Services

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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Services

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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Services

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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