Process
Automation Solutions
Process Automation Solutions Built for Real-World Manufacturing
Malisko delivers process automation solutions for food & beverage, life sciences, and industrial manufacturers — backed by 30 years of systems integration expertise. From single-unit operations to plant-wide control, we design and deploy automation systems that perform reliably, scale with your business, and put data exactly where you need it.
As technology evolves, there’s a greater need for tight integration between devices and the rest of an organization. Your company needs process automation solutions that are easy to use, maintain and secure. Malisko provides industrial automation and control solutions through continuous or batch processing, utilities, packaging or common industrial protocol (CIP). Our team aims to understand your unique applications and provide the excellent technical support you need to thrive.
Why Process Automation Can’t Wait
The manufacturing industry is at an inflection point. Legacy control systems that were installed 20 or 30 years ago are reaching the end of their supported lifecycles, with aging hardware that is increasingly difficult to maintain and software platforms that no longer receive vendor support. At the same time, regulatory requirements are tightening, energy costs are rising, and the workforce that understood those old systems is retiring.
Modernizing your process automation is not just a technology decision — it is a business continuity decision. Companies that delay migration risk unplanned downtime from obsolete hardware failures, compliance exposure from unsupported software, and a growing gap in the data visibility that modern operations demand.
Common Triggers for Process Automation Projects
- Aging or end-of-life DCS or PLC platforms with no available replacement parts
- Lack of real-time data visibility needed for quality, compliance, or operational decisions
- Regulatory changes requiring validated, electronic records for manufacturing processes
- Acquisition or consolidation of facilities requiring standardization across sites
- Expansion of production capacity or addition of new product lines
- Energy or sustainability goals that require tighter process control and monitoring
Our Process Automation Solutions and Consulting Services
Malisko’s manufacturing automation solutions improve how information is shared to increase your business’s productivity. We securely connect your organization using an open-systems approach and with the goal of providing a solution that’s efficient, effective and precise.
Malisko can provide numerous services supporting successful process automation, including the following:
- Developing Process Flow Diagrams (PFDs)
- Developing Piping and Instrumentation Drawings (P&IDs)
- Creating Operational and Functional Process Descriptions
- Design and deployment of Distributed Control Systems (DCSs)
- Migration of legacy control systems to contemporary platforms
- Deploying the ISA S-88 methodology for Batch
- Utilizing Advanced Process Control (APC) and Model Predictive Control (MPC) where applicable
- Utilizing industry-standard Process (Control) Libraries for consistency and efficiency
- Designing and deploying Automation Solutions complementary to meeting Regulatory Compliance
Benefits of Industrial Automation and Control
When you work with us and choose our process automation solutions, your organization enjoys the following benefits:
- Better decision-making: We keep your business needs and goals in mind when developing automation solutions, allowing you to make better decisions about your company’s progress and future.
- Increased efficiency: Automation helps your entire team work faster, so efficiency and productivity see an overall boost.
- More competitiveness: As more companies embrace automation, you must do the same to remain competitive.
- Increased security: Your company needs to share information across multiple operations, and you need to know that the data is secure and protected. Our automation solutions help you connect securely so you can send and receive real-time information without fear of it being intercepted by unauthorized parties.
Process Automation Expertise Across Key Industries
Process requirements vary significantly from one industry to the next. Malisko has deep experience designing and deploying automation systems across the following verticals — and we bring industry-specific knowledge to every engagement, not just generic systems integration skills.
Food & Beverage
From batch cooking and blending to CIP/SIP control and recipe management, we automate food and beverage processes with a focus on consistency, food safety compliance, and throughput efficiency. Our ISA-88 batch expertise is particularly valuable for manufacturers running complex, multi-product operations.
Life Sciences
Pharmaceutical, biotech, and nutraceutical manufacturers require process automation systems that meet FDA validation requirements. Malisko integrates CSV documentation into every life sciences project, ensuring your systems pass regulatory audits and your electronic records meet 21 CFR Part 11 requirements.
Dairy
Dairy processing demands precise temperature control, rigorous CIP validation, and seamless integration between processing and packaging systems. We bring dairy-specific automation knowledge to every project, from fluid milk and cheese to cultured products and ice cream.
Specialty Chemical
Chemical processing environments require automation systems that are designed for hazardous areas, integrated with safety instrumented systems, and capable of managing complex multi-product batch recipes. Malisko brings ISA-88 batch expertise and hazardous area design experience to chemical automation projects.
Platforms We Work With
Malisko is platform-agnostic, which means we select the right technology for your application — not the technology we are most comfortable selling. That said, our team has deep expertise across the leading process automation platforms in the industry.
- Rockwell Automation PlantPAx — DCS built on the ControlLogix platform, ideal for manufacturers standardized on Rockwell infrastructure
- Emerson DeltaV — widely used in life sciences and pharmaceutical manufacturing for its built-in batch and regulatory compliance capabilities
- Emerson Ovation — purpose-built for power generation and water/wastewater applications
- Siemens PCS 7 and SIMATIC — strong choice for large-scale continuous and batch process applications
- Schneider Electric EcoStruxure Process Expert — for manufacturers running legacy Modicon or Schneider infrastructure
- Inductive Automation Ignition — increasingly used as a flexible, cost-effective SCADA and batch platform for mid-size manufacturers
Process Automation Solutions Built for Real-World Manufacturing
Malisko delivers process automation solutions for food & beverage, life sciences, and industrial manufacturers — backed by 30 years of systems integration expertise. From single-unit operations to plant-wide control, we design and deploy automation systems that perform reliably, scale with your business, and put data exactly where you need it.
As technology evolves, there’s a greater need for tight integration between devices and the rest of an organization. Your company needs process automation solutions that are easy to use, maintain and secure. Malisko provides industrial automation and control solutions through continuous or batch processing, utilities, packaging or common industrial protocol (CIP). Our team aims to understand your unique applications and provide the excellent technical support you need to thrive.
Why Process Automation Can’t Wait
The manufacturing industry is at an inflection point. Legacy control systems that were installed 20 or 30 years ago are reaching the end of their supported lifecycles, with aging hardware that is increasingly difficult to maintain and software platforms that no longer receive vendor support. At the same time, regulatory requirements are tightening, energy costs are rising, and the workforce that understood those old systems is retiring.
Modernizing your process automation is not just a technology decision — it is a business continuity decision. Companies that delay migration risk unplanned downtime from obsolete hardware failures, compliance exposure from unsupported software, and a growing gap in the data visibility that modern operations demand.
Common Triggers for Process Automation Projects
- Aging or end-of-life DCS or PLC platforms with no available replacement parts
- Lack of real-time data visibility needed for quality, compliance, or operational decisions
- Regulatory changes requiring validated, electronic records for manufacturing processes
- Acquisition or consolidation of facilities requiring standardization across sites
- Expansion of production capacity or addition of new product lines
- Energy or sustainability goals that require tighter process control and monitoring
Our Process Automation Solutions and Consulting Services
Malisko’s manufacturing automation solutions improve how information is shared to increase your business’s productivity. We securely connect your organization using an open-systems approach and with the goal of providing a solution that’s efficient, effective and precise.
Malisko can provide numerous services supporting successful process automation, including the following:
- Developing Process Flow Diagrams (PFDs)
- Developing Piping and Instrumentation Drawings (P&IDs)
- Creating Operational and Functional Process Descriptions
- Design and deployment of Distributed Control Systems (DCSs)
- Migration of legacy control systems to contemporary platforms
- Deploying the ISA S-88 methodology for Batch
- Utilizing Advanced Process Control (APC) and Model Predictive Control (MPC) where applicable
- Utilizing industry-standard Process (Control) Libraries for consistency and efficiency
- Designing and deploying Automation Solutions complementary to meeting Regulatory Compliance
Benefits of Industrial Automation and Control
When you work with us and choose our process automation solutions, your organization enjoys the following benefits:
- Better decision-making: We keep your business needs and goals in mind when developing automation solutions, allowing you to make better decisions about your company’s progress and future.
- Increased efficiency: Automation helps your entire team work faster, so efficiency and productivity see an overall boost.
- More competitiveness: As more companies embrace automation, you must do the same to remain competitive.
- Increased security: Your company needs to share information across multiple operations, and you need to know that the data is secure and protected. Our automation solutions help you connect securely so you can send and receive real-time information without fear of it being intercepted by unauthorized parties.
Process Automation Expertise Across Key Industries
Process requirements vary significantly from one industry to the next. Malisko has deep experience designing and deploying automation systems across the following verticals — and we bring industry-specific knowledge to every engagement, not just generic systems integration skills.
Food & Beverage
From batch cooking and blending to CIP/SIP control and recipe management, we automate food and beverage processes with a focus on consistency, food safety compliance, and throughput efficiency. Our ISA-88 batch expertise is particularly valuable for manufacturers running complex, multi-product operations.
Life Sciences
Pharmaceutical, biotech, and nutraceutical manufacturers require process automation systems that meet FDA validation requirements. Malisko integrates CSV documentation into every life sciences project, ensuring your systems pass regulatory audits and your electronic records meet 21 CFR Part 11 requirements.
Dairy
Dairy processing demands precise temperature control, rigorous CIP validation, and seamless integration between processing and packaging systems. We bring dairy-specific automation knowledge to every project, from fluid milk and cheese to cultured products and ice cream.
Specialty Chemical
Chemical processing environments require automation systems that are designed for hazardous areas, integrated with safety instrumented systems, and capable of managing complex multi-product batch recipes. Malisko brings ISA-88 batch expertise and hazardous area design experience to chemical automation projects.
Platforms We Work With
Malisko is platform-agnostic, which means we select the right technology for your application — not the technology we are most comfortable selling. That said, our team has deep expertise across the leading process automation platforms in the industry.
- Rockwell Automation PlantPAx — DCS built on the ControlLogix platform, ideal for manufacturers standardized on Rockwell infrastructure
- Emerson DeltaV — widely used in life sciences and pharmaceutical manufacturing for its built-in batch and regulatory compliance capabilities
- Emerson Ovation — purpose-built for power generation and water/wastewater applications
- Siemens PCS 7 and SIMATIC — strong choice for large-scale continuous and batch process applications
- Schneider Electric EcoStruxure Process Expert — for manufacturers running legacy Modicon or Schneider infrastructure
- Inductive Automation Ignition — increasingly used as a flexible, cost-effective SCADA and batch platform for mid-size manufacturers
Frequently Asked Questions About Smart Manufacturing
Still have questions about smart manufacturing? We can answer them.
What is manufacturing intelligence and how is it different from regular reporting?
Smart manufacturing applies the Industrial Internet of Things (IIoT) to the production process. Manufacturing intelligence goes beyond static reports. It involves continuously collecting, contextualizing, and presenting operational data in ways that support real-time decisions. Where traditional reporting tells you what happened after the fact, a well-designed manufacturing intelligence system tells you what is happening now — and often why — so your team can act before a problem becomes a loss.
Do we need to replace our existing control systems to get started?
Not necessarily. Malisko specializes in integrating manufacturing intelligence solutions with existing infrastructure — including legacy historians, PLCs, DCS systems, and ERP platforms. In many cases, the data you need is already being collected; the gap is in how it is structured, presented, and made available to the people who need it.
How long does a manufacturing intelligence project typically take?
Project timelines vary based on scope, the number of data sources being integrated, and the complexity of the reporting requirements. A focused dashboard or reporting project for a single line or facility can often be completed in weeks. Enterprise-scale deployments across multiple sites are phased over several months. Malisko works with you during the front-end design phase to define scope and set realistic project timelines. The easiest way to start with smart manufacturing is to partner with a company that offers a full suite of automation and IoT services, such as Malisko.
Can manufacturing intelligence solutions be accessed remotely or on mobile devices?
Yes. Modern manufacturing intelligence platforms support web-based and mobile access, allowing managers and executives to view production KPIs, alerts, and reports from anywhere. Malisko designs solutions with your access requirements in mind, whether that means plant-floor displays, office dashboards, or remote mobile access.
What is the difference between a DCS and a PLC-based control system?
A Distributed Control System (DCS) is designed for complex, continuous process applications — think chemical plants, pharmaceutical manufacturing, or large food and beverage facilities with many interdependent control loops. DCS platforms excel at managing hundreds or thousands of I/O points with tight integration between control, alarming, and historian functions. PLC-based systems (often combined with SCADA) are more common in discrete and hybrid manufacturing environments where the emphasis is on machine-level control and sequencing. Malisko has expertise in both architectures and can help you determine which approach best fits your process requirements.
How disruptive is a DCS migration? Can we do it without shutting down production?
Migration complexity depends on the size of your system, the criticality of the process, and the gap between your existing platform and the target architecture. Malisko uses a structured migration methodology that prioritizes production continuity — including parallel operation strategies, phased cutover plans, and thorough simulation and testing before any live changes. Many migrations can be executed during planned maintenance windows, minimizing impact on production schedules.
Can Malisko help us make the business case for a process automation investment?
Yes. We regularly support clients in building the justification for automation projects, including ROI modeling, energy savings projections, downtime cost analysis, and compliance risk assessments. A front-end engineering design (FEED) engagement is often the right first step — it gives you the engineering detail needed to develop an accurate capital estimate and a clear picture of the expected return.
Contact Malisko for Process Automation Solutions Today
We want to be more than just an industrial automation consultant. When you partner with us, you’ll have a full-fledged team member ready to support you throughout the automation process. Contact us today to learn more.
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