Case Studies
Keeping Production on Track with Hands-On Technical Training in Schuylkill County
When a specialty food manufacturer in Schuylkill County faced staffing gaps that put production at risk, they called FrommConnect for help. Our team delivered hands-on, on-site technical training tailored to the facility’s real-world systems. From PLC troubleshooting to network setup and software updates, we empowered their staff to keep operations running confidently and independently.
Upgraded Operating Systems & Automation Applications for Schuylkill County Wastewater Treatment Center
FrommConnect helped a Schuylkill County wastewater treatment plant modernize its automation systems and operating infrastructure. By upgrading outdated SCADA software, migrating historical data to a modern SQL database, and implementing a seamless transition plan, the facility now benefits from improved efficiency, reduced downtime, regulatory compliance, and lower operating costs—all without service disruption.
Optimization of Production Line Software for Aluminum Can Manufacturer
When a leading aluminum can manufacturer struggled to integrate a new can-stacker and faced software challenges with its palletizing system, FrommConnect provided the expertise needed to get production back on track. By developing a custom PLC control scheme and simplifying conveyor system software, FrommConnect helped streamline operations, reduce downtime, and pave the way for future automation enhancements.
Infrastructure Upgrades for a Global Pharmaceutical Manufacturer
FrommConnect partnered with engineering firms to support a global pharmaceutical manufacturer in modernizing its environmental monitoring systems. Facing obsolete technology and tight deadlines, the customer relied on FrommConnect’s UL-certified panel shop to fabricate, wire, and test custom control panels with precision. Using our automated Hoffman ModCenter, we delivered accurate builds on time—helping streamline compliance and safeguard product quality.
Optimization of a Soda Bottling Plant’s Production Line
FrommConnect helped a soda bottling plant eliminate costly downtime by automating a key failure point in its production line. Previously, a misaligned bottle would halt the entire operation. By installing a three-sensor bracket and integrating FactoryTalk Optix, the system now detects and ejects faulty bottles automatically—keeping the line moving and boosting overall efficiency.
Modernization of a Pool Manufacturer’s Production Line
FrommConnect modernized a 12-stage production line for a leading pool manufacturer by upgrading to Rockwell Automation ControlLogix PLCs and FactoryTalk ME HMIs. The upgrade enabled centralized control and real-time data access, improving safety, efficiency, and visibility across the line. Technicians can now operate all stages from a single interface—eliminating manual station control and reducing downtime.
Fabricating 94 Control Panels for Battery Manufacturer
FrommConnect fabricated and assembled 94 stainless steel control panels for a leading battery manufacturer, supporting safety upgrades in their charging process. Using our Hoffman ModCenter, we delivered clean, consistent panel cutouts—far faster and safer than manual methods. We also installed specialized third-party hardware and provided just-in-time shipping with warehouse storage to match the customer’s phased installation schedule.
Modernizing Production Lines for a Metal Processing Plant
FrommConnect upgraded outdated PLCs, VFDs, and HMIs at a Beryllium processing facility, modernizing control of two critical DC motors. The project eliminated the risk of extended downtime due to obsolete parts by transitioning to Rockwell Automation’s ControlLogix and FactoryTalk Optix platform. Completed in two budget-conscious phases, the upgrade ensured long-term reliability, serviceability, and production continuity.
Custom VFD Enclosures for Toll Processor
FrommConnect designed and built a custom enclosure for a toll processor’s new milling system in Virginia. The enclosure housed two 480V three-phase VFDs and was engineered to manage heat and dust from the milling process. As a full-service UL-certified panel shop, FrommConnect handled the entire project—from schematics and panel cuts to wiring, testing, and delivery—ensuring precision, safety, and compliance.