Plant sensor monitoring
Continuous logging replacing manual gauge readings.
Industrial Automation Systems
Sensor monitoring, data logging, smart controllers, motor control and relay systems for industrial embedded automation.
Overview
What this service covers
We design embedded controllers and monitoring hardware for industrial processes — the sensor input, control output, and data logging in between, built to survive a plant-floor environment rather than a lab bench.
Client Problems
Problems this service solves
- A process is still monitored manually or on paper.
- An off-the-shelf automation controller doesn't fit the specific application or budget.
- A custom controller is needed because standard hardware doesn't match the process.
- Data logging needs to survive plant-floor electrical noise instead of dropping readings.
Capabilities
What we do
- Sensor monitoring and data logging
- Smart controller and relay design
- Motor control interfaces
- RS-232 / RS-422 / RS-485 and CAN interfaces
- Modbus integration where applicable
- Alarm and threshold logic
- Panel-ready embedded automation boards
Technologies
Tools & platforms
STM32 and ESP32 controllers, RS-485/Modbus interfaces, and isolated signal-conditioning components chosen for reliability on noisy industrial power.
STM32 / ESP32RS-485 / ModbusRelay & motor control
Development Process
How we approach an automation project
- 01Process review
Understand what's being sensed, controlled and logged today.
- 02Controller architecture
Design the sensor, control and interface layout.
- 03Hardware & firmware build
Build and bench-test the controller.
- 04Commissioning support
Support installation and validation on site.
Deliverables
What you receive
- Schematics and PCB layout, where custom hardware is built
- Firmware source code
- Wiring and interface documentation
- Commissioning notes
Testing & Validation
How automation hardware gets validated
Controllers are bench-tested against simulated sensor inputs across their full expected range, not just a single "it works" reading, and signal-conditioning circuits are checked for noise immunity before anything goes near a live process. Where commissioning support is part of the scope, the final validation happens on site against the actual process signals, since a plant floor rarely matches a bench setup exactly.
Applications
Where this is used
Motor & relay control panels
Custom control hardware for process equipment.
Alarm systems
Threshold-based alerts for out-of-range conditions.
Related Services
Often paired with
4-20mA Signal Systems
Analogue sensor interfacing for the same control panel.
PCB Design
Custom controller boards for the automation hardware.
Embedded Firmware Development
The control logic running on the automation hardware.
How We Can Help
How PAK-EL LAB Can Help
If a process is still monitored manually, or an off-the-shelf controller doesn't fit the application, we can design the sensor interface, controller and firmware as one project rather than three separate hand-offs. Scope, deliverables, schedule and quotation are confirmed once we understand what's being sensed, controlled and logged today — those details shape the design too much for a generic estimate to be useful. We work with clients internationally and collaborate remotely as standard practice.
See also: Portfolio · 4-20mA Signal Systems · Contact
FAQ
Frequently Asked Questions
Can you retrofit a custom controller to replace an aging PLC?
Yes, where a standard PLC doesn't fit the application or budget, we can design a purpose-built controller around the exact sensors and outputs the process needs.
Do you support RS-485/Modbus integration with existing systems?
Yes, we design RS-485/Modbus interfaces to integrate new controllers with existing SCADA or plant-monitoring systems where that protocol is already in use.
Will the controller hold up to plant-floor electrical noise?
That's a core design constraint, not an afterthought — isolated signal conditioning and careful grounding are built in from the schematic stage for exactly this reason.
Do you also build the enclosure or panel hardware?
We design panel-ready boards; enclosure and panel integration is scoped per project depending on what you already have on site.
Discuss Your Automation Project
Tell us what's being monitored or controlled today, and what needs to change.