Custom system control
Custom system controls for food & pharmaceutical industries
Custom system control for complete material handling integration
Custom system control solutions from Coperion and Coperion K-Tron provide fully integrated automation for conveying, feeding, batching, and plant-wide material handling. Engineered in-house and built with Allen-Bradley or Siemens PLCs, these custom controls deliver reliable performance, seamless connectivity, and complete visibility across food, pharmaceutical, and processing applications.
Benefits:
- Total system integration
- Expertise with Allen-Bradley and Siemens PLCs and HMIs
- Support for EtherNet/IP, PROFIBUS, PROFINET, and other protocols
- Personalized, responsive technical support
- Turnkey control solutions
- Capabilities include batch control, sequencing, lot tracking, recipe management, inventory monitoring, and more
Capabilities:
- Custom programming
- Plug and play connection points
- Seamless interface between pneumatics and feeders
- Process and flow operating procedures
- High levels of accuracy
- Bench testing
- Simulation testing for custom programs
- Load analysis
- Complete documentation
- Enclosure layout (internal and external)
- Schematic wiring diagrams (JIC standards)
- Remote connection diagrams
- One-line or three-line power diagrams
- Electrical system flow
- Network diagram
- FAT and SAT
This system is compatible with plastics, chemicals, and mineral processing applications. For more details, please visit the custom system control page on Coperion performance material website.
- Overview
- Features
- Options
- Gallery
Coperion’s custom system controls provide a fully integrated automation platform designed for plant-wide material handling. They are built using advanced PLC technology and engineered in-house to ensure reliable performance for conveying, feeding, batching, and sequencing operations.
Flexible and fully customizable
Every system is tailored to fit the facility’s layout, equipment mix, and process requirements. In addition, controls support Allen-Bradley and Siemens PLCs and HMIs. This design also minimizes wiring, simplifies installation, and enables fast commissioning. Modern communication protocols, including EtherNet/IP, PROFIBUS, and PROFINET, ensure seamless connectivity across pneumatic systems, feeders, and higher-level plant networks. Optional VPN access allows secure remote service and diagnostics.
Reliable performance for complex operations
Custom system controls support a wide range of operations, from simple transfer tasks to advanced multi-step production processes. Furthermore, these systems offer key features such as batch control, sequencing, recipe management, lot tracking, and inventory monitoring. Custom programming, bench testing, and simulation guarantee stable and accurate operation before startup.
Control system categories
- Simple pneumatic conveying control – Compact PLC-based control for basic conveying needs, fully customizable.
- Multiple source / destination conveying control – Manages multiple systems and integrates up to six KCM feeders via EtherNet/IP.
- Plant-wide system controls – Fully engineered automation solution with unlimited I/O expansion and broad hardware options.
Simple pneumatic conveying
Provides a basic control solution for pneumatic conveying using an Allen-Bradley or Siemens PLC with an onboard 7″ LCD HMI. Other PLC and HMI brands are available upon request.
Base unit specifications (fully customizable):
- VPN industrial Ethernet module: Optional
- Input: 20 / Output: 28
- I/O expansion modules: Up to 7
- Built-in Ethernet connection: Yes
- Enclosure: 24″H × 24″W × 8″D
Multiple source / Destination pneumatic conveying
Provides a control system for multiple material handling points and up to six Coperion K-Tron KCM feeder controllers via EtherNet/IP, using an Allen-Bradley or Siemens PLC with a 10″ LCD HMI. Other PLC and HMI brands are available upon request.
Base unit specifications (fully customizable):
- VPN industrial Ethernet module: Optional
- Input: 32 / Output: 32
- I/O expansion modules: Up to 4
- Built-in Ethernet connection: Yes
- Enclosure: 36″H × 36″W × 8″D
Plant-wide system controls
Provides a fully customized control system utilizing a wide selection of PLCs, HMIs, VPN industrial Ethernet routers, and more. Capabilities include pneumatic conveying, material handling, batch control, sequencing, recipe management, lot tracking, inventory control, and additional plant-wide functions.
Base unit specifications (fully customizable):
- Input: 32+ / Output: 32+
- I/O expansion modules: Unlimited
- Built-in Ethernet connection: Yes
- Enclosures: Built to specification
- VPN industrial Ethernet module: Standard
- Various categories of compliance (ATEX, UL/CUL, CE and others)
- Motor starter panels
- Timer panels
- VFD panels
- Remote I/O panels
- Multi lingual HMI’s and controls
- Motor control centers
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