Transforming crushing plant operations through integrated automation.
Controlgear Instramac was engaged to deliver the electrical control and automation systems for a new crushing plant within the minerals processing sector. The project scope included the design, manufacture, testing and commissioning of containerised motor control centres (MCCs), PLC systems, HMI platforms and SCADA infrastructure. The objective was not simply to provide motor control equipment, but to create a modern automation platform capable of supporting efficient plant operation, improved reliability, and future operational growth.
Project Outcome:
The completed system transformed the plant from a traditionally operator-dependent operation into a fully integrated automation environment.
Historically, many crushing plants rely heavily on operators to manually start, stop and manage equipment using conventional DOL starters and VSDs. The new solution introduced intelligent plant control through automated routing, interlocking, and alarming strategies.
Key outcomes included:
• Automated plant routing and operational sequencing.
• Equipment interlocking to protect process integrity and reduce operational risk.
• Alarm management for abnormal operating conditions.
• Monitoring functionality to help prevent blockages and spillages.
• Preventative maintenance notifications and operational insights.
• Historical trending and reporting capability.
• Remote access functionality for plant owners and support personnel.
• Improved operational consistency through reduced dependence on operator intervention.
The result is a modern control platform that provides greater visibility, reliability and operational efficiency across the crushing process.
Biggest challenge and solution:
The biggest challenge was developing a control philosophy capable of integrating multiple plant areas into a single coordinated automation system.
Before detailed engineering commenced, standard MCC control circuit philosophies and typical designs were developed and reviewed with the client. In parallel, a complete control system architecture was established, defining the PLC, HMI, SCADA and communications infrastructure required for the facility.
Once these standards were agreed, detailed MCC, PLC and SCADA engineering was completed. The resulting designs were then used to optimise the layout and sizing requirements of the client-supplied E-houses.
This structured engineering approach reduced project risk and ensured consistent implementation across all control systems.
Key technologies:
• Schneider Electric Modicon M340 PLC platform.
• Schneider Electric X80 distributed I/O.
• Schneider Electric TeSys motor control technologies, ATS480 soft starters, and ATV340 variable speed drives.
• Schneider Electric power distribution and protection equipment.
• Schneider Electric HMI with Ecostructure Operator Terminal Expert.
• EcoStructure Machine SCADA Expert.
• Integrated Ethernet communication architecture.
• Remote access capability for operational support.
One thing we would do differently:
If we received the full turnkey project, we would have integrated and leveraged our end-to-end capabilities providing a better ROI and maximised total project value.
Unique selling point:
The project demonstrates how a structured automation strategy can transform a conventional crushing plant into an intelligent process facility. By combining MCC design, PLC control, HMI development, SCADA visualisation and remote connectivity within a unified Schneider Electric platform, Controlgear Instramac delivered a scalable solution that provides operational visibility, improved reliability and a foundation for future digitalisation initiatives.
For more information Controlgear Instramac (CGI) Tel:
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