Industry Automation Platform
Industrial Automation & Smart Tanning Control System
Transforming a legacy automation system into a scalable and future-ready platform
Team
5Duration
12 monthsCountry
SwitzerlandIndustry
Industrial Automation
Modernizing Industrial Automation Systems
One of the biggest projects in automation we were a part of. Client already had a system installed but with very high maintenance requirements. Part of the system were implemented in different methods and technologies and our job was to build a new version which should be easy maintainable and scalable.
Next to high maintenance problems with previous version, client was also blocked from delivering new features to the clients.
Biggest challenges in this project were integration with PLC system and extensive validation and testing of the process, even smallest mistakes could cause mayor failures in the system. We collaborated with the client on one of the most complex automation projects we have worked on.
The client already had an existing system, but it required high maintenance, lacked scalability, and was preventing them from delivering new features to their customers. Parts of the old system were built with different approaches and technologies, which created inconsistency and complexity.
Our task was to build a new, modern, scalable version that reduces maintenance needs and allows the client to continue innovating. A major challenge was the integration with the PLC (Programmable Logic Controller) system and ensuring extensive validation and testing — since even the smallest mistake could create serious failures in production.
Tech Stack
.NET ASP.NET Core (Web API), Entity Framework Core
C# (ASP.NET Core)
SQL Server
Challenges
Legacy system built using multiple inconsistent technologies.
Very high maintenance requirements that slowed down operations.
Client was unable to deliver new features due to outdated architecture.
Complex integration with the PLC system, requiring absolute precision.
Extremely sensitive production processes — even minor errors could cause system-wide failures.
Need for strict validation and testing cycles to ensure safe operation.
Solution
Rebuilt the entire system using a modern, unified, scalable architecture.
Introduced standardized development practices to replace fragmented legacy solutions.
Implemented reliable integration with PLC systems ensuring safe and precise automation.
Designed a system optimized for low maintenance and easy monitoring.
Conducted extensive validation and testing cycles to ensure production safety and stability.
Enabled long-term growth by creating a platform ready for new features, IoT integrations, and automation enhancements.
Benefits
Benefits of the solution and partnership with IT Engine
More stable and predictable production processes.
Reduced system downtime thanks to better automation and improved reliability.
Faster delivery of new features and improvements.
Enhanced safety due to strict process validation and error-proofing.
Smooth and intuitive user experience across the new platform.
Significantly reduced maintenance costs due to unified architecture.
Consistent development approach replacing previously fragmented solutions.
Faster time-to-market for new functionalities.
Improved operational efficiency through automated workflows.
Long-term partnership with full technical support, improvements, and consultations.
New architecture designed for easy expansion into additional production lines.
Maintainable system setup that supports continuous upgrades.
Flexibility to integrate additional hardware, sensors, or new PLC modules.
Prepared for IoT-driven enhancements and Industry 4.0 requirements.
Solid foundation enabling the client to grow their automation ecosystem.
What our client said
Huni AG
Great, creative and professional team! Working with IT Engine is always a pleasure because it gives successful results and positive outcome. We worked with IT Engine team on various projects and there are many more yet to come. This positive experience of ours is based on a highly professional approach to work which this team has, their technical solutions and suggestions. That is why we trust IT Engine for each and every project and cooperation in the future, and would recommend them to everyone.
