Plant Floor Control and Process Automation

Manufacturers face pressure to increase throughput and reduce unplanned downtime while managing the complexity of aging control systems and evolving production demands. Malisko is a CSIA-certified process automation system integrator that designs and deploys industrial control systems that optimize production performance and minimize downtime.

Plant Floor Control Solutions

Malisko builds scalable architectures aligned to the realities of each facility, allowing production teams to have the control and insight they need to operate consistently and respond quickly when conditions change.

We deliver:

• PLC, DCS and PAC programming and configuration services: Our experts develop sequenced, deterministic control logic for machine-level and distributed process control applications, reducing process variability and providing operations teams with consistent, repeatable performance.
• SCADA and HMI design: We design machine-level HMIs and distributed, server-based SCADA architectures that deliver real-time production visibility and allow alarms and events management, enabling faster decisions and quicker response to unexpected conditions across the line.
• Electrical and control panel design: Our team designs and builds purpose-built power distribution and control infrastructure, including motor control centers and variable frequency drives, that support power management across drive and motor applications.
• Process instrumentation and I/O architecture: We deploy field-level signal acquisition systems that deliver data acquisition across analog and digital signals.
• Historian and real-time data collection for reporting and dashboards: Our data infrastructure solutions provide access to the time-series and event-based information operations and production teams can use to identify inefficiencies, support root cause analysis and drive continuous improvement.

Process Automation Solutions

Our expertise in continuous and batch process automation includes:

• ISA-88 batch control and ISA-95 enterprise-control system integration: We implement standardized, recipe-driven production frameworks that reduce batch-to-batch variability and enable seamless IT/OT data exchange, delivering production intelligence to operational and business decision-making levels.
• Rockwell Automation PlantPAx modern DCS implementation: Our team designs and deploys scalable, plant-wide distributed control architectures within a unified environment, providing the flexibility manufacturers need to expand and adapt as production requirements evolve.
• PID loop tuning and control across flow, temperature, pressure and level applications: We optimize loop performance to tighten process control, reduce off-spec production and protect yield across critical process variables.
• Comprehensive documentation and validation services: Our documentation practice produces rigorous, audit-ready deliverables, including IQ/OQ/PQ protocols, P&IDs, process flow diagrams, loop diagrams, and functional specifications, designed for FDA-regulated and GAMP 5-aligned environments.

Industries We Serve

Malisko delivers plant floor control and process automation solutions to manufacturers across a range of process-intensive verticals, each with distinct operational and compliance demands:

• Food and beverage: Deploy batch automation and sanitary process control systems for Pasteurized Milk Ordinance (PMO) environments.
• Life sciences and pharmaceutical: Implement control systems and documentation for FDA-regulated environments, with architecture structured to align with GAMP 5 guidelines.
• Consumer packaged goods: Integrate high-speed packaging lines, maximize throughput and minimize line changeover time at scale.
• Specialty chemical: Maintain precise continuous process control, address hazardous area classification requirements and integrate process safety into the control architecture.

Why Businesses Choose Malisko

Malisko provides technical excellence across complex, large-scale automation programs. Over the years, we have worked on various plant floor control and process automation projects. 

For example, we partnered with a national dairy producer to deploy a comprehensive PlantPAx-based automation solution that replaced paper-based PMO records with an electronic reporting suite, reduced clean-in-place cycle times and chemical usage, and accelerated maintenance troubleshooting.

We also stand apart by providing:

• Multiplatform expertise: Our knowledge spans multiple automation platforms and control architectures. This expertise means we select solutions for fit and manufacturers get the right technology for their operation.
• Full life cycle support: From initial design and implementation to technical support, our team remains a committed partner post implementation.
• Trusted industry partnerships: Our partnerships with hardware and software solution providers, such as Rockwell Automation allow us to bring vetted technologies to our projects.

Request Industrial Control System Integration

Contact Malisko to schedule a plant floor assessment and receive a tailored approach for your facility.