Modernising Vertical Filter Press Machines with Future-Focused Control Systems
January 2026System Integration & Control Systems Design
Project and Industry
Pressure Filter Specialists approached us to modernise vertical filter press machines for the Minerals and Metals industry. The goal was to improve reliability, reduce downtime, and implement a future-focused PLC/SCADA system that supports remote monitoring and analytics.
Project Outcome
Standard filter press designs typically house multiple units – water station, hydraulic station, and filter press – in a single electrical and control panel. This complicates fault-finding and increases machine downtime.
For this modernisation, each unit was packaged into its own dedicated panel, providing:
• Easier maintenance and fault isolation
• Flexible installation where space is limited
• A modernised PLC/SCADA solution capable of remote data collection and performance analytics, ensuring long-term operational insight
Biggest Challenge and Our Solution
Two main challenges emerged:
1. Migration of 35-year-old electrical drawings – The original drawings had limited information. We extracted core data (motor sizes, breaker ratings, etc.) and migrated the system into standardised E-plan templates.
2. Migration of undocumented PLC software – The previous PLC software had evolved over decades with no manual or design documentation. We created a simulated version of the existing software and reproduced its functionality using our in-house PLC/SCADA library developed by Scibotron.
These solutions ensured accurate modernisation while retaining critical functionality and reliability.
Key Technologies and Tools Used
• Siemens S7-1500 PLC platform
• Siemens WinCC Open Architecture SCADA
• In-house developed PLC/SCADA software library
• Migration-ready design approach for future adaptations, including potential Allen-Bradley deployments
One Thing We’d Do Differently
Physically verify drawings against the existing machine during panel assembly. During this project, mismatches required adjustments to switchgear that could have been anticipated with early verification.
Unique Selling Point
A proudly South African solution: while similar filter press systems are offered by international suppliers, they often provide limited local support. Our solution ensures customers in remote locations with limited internet connectivity have reliable access to technical support.
Project Highlights
• Dedicated electrical panels per process unit for improved serviceability
• Modern PLC/SCADA architecture with remote monitoring and analytics
• Proven reliability in challenging operational and remote environments
Project and industry
System Integration & Control Systems Design
XEL EE was contracted to deliver the complete electrical, control and instrumentation scope for the upgrade of a gold mine's water treatment facilities in Tanzania.
Read more...Turning system integrators into trusted technology partners Schneider Electric South Africa
IT in Manufacturing System Integration & Control Systems Design
Schneider Electric’s Alliance Partner Programme is repositioning system integrators from hardware suppliers into lifecycle-value partners. Oriel Soupen explains the competency framework, certification model and real-world results that are already helping African system integrators win higher-value, longer-term engagements.
Read more...When digital twins move from concept to critical tool
IT in Manufacturing System Integration & Control Systems Design Maintenance, Test & Measurement, Calibration
Digital twins are moving out of the lab and onto the mine, the factory floor and the transport network where they predict failures before they happen. Amritesh Anand looks at where they earn their keep, the data and integration work behind them, and the security questions every organisation should ask before switching one on.
Read more...Best practices for managing the MRO supply chain in Africa RS South Africa
System Integration & Control Systems Design
RS South Africa outlines how strong data governance and digital tools can turn maintenance, repair and operations procurement into a strategic advantage across Africa.
Read more...Containerised Solar Solution Accelerates Delivery of Riverside 3 MW Power Plant Proconics
System Integration & Control Systems Design
Proconics was engaged by NewFields to deliver the electrical integration solution for the Riverside 3 MW Solar Power Plant in Zimbabwe. The project required a compact, modular approach that could simplify deployment, minimise site works, and support rapid commissioning in a remote location.
Read more...Modern Energy Metering Solution Enhances Reliability and Reporting for Major Power Utility SAM Systems Automation & Management
System Integration & Control Systems Design
This project involved the implementation of a modern energy metering system for a major power utility operating within the industrial automation and energy management sector. The objective was to improve the reliability, accessibility, and accuracy of energy data while simplifying infrastructure and reducing system complexity.
Read more...PCS Global PCS Global
System Integration & Control Systems Design
PCS Global led a digital infrastructure initiative in a southern African data centre setting, aiming to merge several essential operational systems into one cohesive platform. The objective was to break down silos, enable real-time decisions, and ensure seamless operation in a mission-critical environment.
Read more...Seamless migration from ET 200M to ET 200SP HA for future-ready automation Moore Process Controls
System Integration & Control Systems Design
Moore Process Controls undertook a modernisation initiative spanning the mining, petrochemical, and oil & gas sectors. This project involved upgrading legacy Siemens ET200M I/O systems to the advanced ET200SP HA platform.
Read more...Project & Industry
System Integration & Control Systems Design Project: Upgrading essential automation and SCADA systems at a coal mine. Outcome: A modern, stable automation and SCADA environment with reduced technical debt and easier support, ready for expansion. ...
While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared for publication. Advertisements and company contact details are published as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity of supplied material.
printer friendly version