PLC Exchange Services
Automation Consulting
One-on-one project planning for automation upgrades, new installations, and system modernization. We help you define the scope, identify the hardware, and build a bid package you can take to any integrator with confidence.
Schedule a ConsultationWhat We Do
PLC Exchange offers one-on-one automation consulting for manufacturers, facility managers, and operations teams looking to automate, upgrade, or modernize their existing systems. Whether you are replacing legacy hardware, planning a new production line, or simply trying to understand what is possible with your current infrastructure, our team brings 15 years of hands-on experience in industrial controls to the conversation.
Our goal is straightforward: help you understand your project inside and out so you can speak fluently with system integrators, make informed purchasing decisions, and maintain full control of your project scope and budget. We work with you to break down every aspect of the project — from hardware selection to electrification to timeline — and deliver a complete bid package that any qualified integrator can execute against.
How It Works
We start with a one-on-one conversation to understand your facility, your current systems, and what you are trying to accomplish. No commitment required — this is an open discussion to define the problem and evaluate the opportunity.
We work through the technical details together: what needs to be automated, what hardware is involved, what infrastructure exists, and what gaps need to be filled. This is where we identify the full scope of work.
We deliver a structured project plan and bid package that you can hand directly to a local system integrator. You walk in prepared — knowing the hardware, the scope, the timeline, and the right questions to ask.
Schedule a Consultation
Tell us about your project and we will reach out to schedule a time to talk. Initial consultations are free.
What We Cover
Hardware Identification
We evaluate your existing equipment and identify what can be reused, what needs to be replaced, and what new hardware is required. This includes PLCs, drives, HMIs, I/O, power distribution, networking, and safety systems.
Project Scope Definition
We help define clear boundaries for the project — what is included, what is excluded, and where the phases break. A well-defined scope is the single most important factor in keeping a project on budget and on time.
Electrification Planning
We review the electrical requirements: panel layouts, power distribution, motor loads, circuit protection, and wiring strategies. This ensures your integrator has the information needed to design and build the electrical infrastructure.
Bill of Materials
We compile a detailed list of every component needed for the project — controllers, I/O modules, drives, sensors, panel hardware, networking equipment, and cabling — with part numbers, quantities, and estimated pricing.
Resource & Timeline Planning
We help estimate the engineering hours, installation labor, commissioning time, and overall project timeline. Understanding the resource requirements upfront prevents surprises during execution.
Integrator Preparation
We prepare you to engage with system integrators on equal footing. You will understand the technical language, know what deliverables to expect, and be able to evaluate proposals and bids with confidence.
Our Experience
Engineering Disciplines
Our team has direct experience across the full project lifecycle:
- Control system design and architecture
- PLC and HMI programming
- Electrical panel design and layout
- System implementation and installation
- Commissioning and startup
- Project management and coordination
Industries Served
We have worked with facilities and operations across a range of sectors:
- Food and beverage manufacturing
- General industrial and discrete manufacturing
- Material handling and conveyor systems
- Oil and gas processing
- Water and wastewater treatment
- Packaging and distribution
Who This Is For
Plant & Facility Managers
You know your operation needs automation or an upgrade, but you are not sure where to start or how to evaluate proposals from integrators. We bridge that gap.
Maintenance Teams
Your legacy systems are becoming harder to support and spare parts are getting scarce. We help plan the migration path to current-generation hardware with minimal disruption.
Operations & Engineering Staff
You have the internal knowledge of how your process works but need help translating that into a structured automation project with clear specifications and hardware requirements.
Frequently Asked Questions
Do you perform the actual integration and installation work?
At this time, our consulting service focuses on project planning, scoping, and bid package development. We prepare you with everything a qualified system integrator needs to execute the work. We can recommend integrators in your area and help you evaluate their proposals. Full execution services are planned for the future.
What does a typical engagement look like?
Most engagements begin with an introductory call to understand your situation and goals. From there, we schedule one or more working sessions to walk through the technical details — existing equipment, desired outcomes, constraints, and budget. The result is a documented project plan and bid package that defines the scope, hardware, timeline, and estimated cost.
How much does consulting cost?
Pricing depends on the complexity and scope of the project. Initial consultations are free — we want to understand your needs before discussing cost. Contact us to schedule a conversation and we will provide a clear estimate based on the work involved.
What industries do you have experience with?
Our team has 15 years of experience spanning food and beverage, general industrial manufacturing, material handling, oil and gas, water/wastewater, and packaging. The fundamentals of controls engineering apply across industries — if it involves PLCs, drives, HMIs, or I/O, we can help.
Can you help with projects that use hardware from manufacturers other than Allen-Bradley and Siemens?
Yes. While our deepest expertise and product inventory is in Allen-Bradley and Siemens platforms, our engineering experience extends to control systems in general. We can consult on projects involving any major automation platform and help you evaluate hardware options regardless of manufacturer.
Ready to talk through your project?
PLC Exchange[email protected]
980-202-0882
Initial consultations are free — no obligation