PLC, DCS, HMI, SCADA HTSE Inc. Process Automation & Machine Control

SCADA control panel

Process & Discrete Control Systems Automation solutions for over 25 years.

packaging line automated process skid field engineers

Industrial IT & Virtualization HTSE Inc. A VMware Partner specializing in SCADA Virtualization

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Vision Inspection & Serialization HTSE Inc. A Systech and Cognex Partner

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Process Automation & Machine Control

Envision, engineer, and execute on time and on budget - project after project.

HTSE provides automation solutions for some of the world's largest (and not so large) pharmaceutical, chemical, food/beverage, medical device, and manufacturing companies. Our intense focus on these industries has resulted in technical fluencies, foresights, and insights honed through 1000+ client projects. We feel your time is valuable, so we have designed this site with speed in mind. Thank you for visiting.

  • ABB

    Channel Solution Partner

  • Cognex
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  • Rockwell Automation
  • Systech
  • VMware
  • Wonderware
ISA
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Services

With automation, things change continuously. The winning formula for keeping up is experience + training. HTSE engineers and IT professionals possess on average, over a decade of real world field experience. We institute continuing employee training programs; this ensures our staff is not only experienced with legacy systems, but also knowledgeable and skilled in the design and deployment of emerging control platforms and technologies.

HTSE engineers and IT professionals possess an average 12+ years of field experience.

  • Process Automation

    Process Automation

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    HTSE has developed, installed, and commissioned a diverse variety of DCS and PLC control platforms for many different processes. Techniques used include advanced algorithms, PIDs, IEC 1131, programming standards development, simulation, startup, and interfacing to databases.

    HTSE and Process Automation
    We have designed and installed hundreds of control systems and developed countless lines of operating logic to control a variety of manufacturing processes and equipment. Our diverse experience with a broad cross-section of hardware platforms and applications has taught HTSE the importance of developing structured programming standards, flexible control code and the importance of utilizing engineering staff that not only have superior programming abilities but a strong knowledge of processes, process equipment and their safe and reliable control. Make sure to review our Representative Process Automation Project Listing.

    Batching and Continuous Process Controls
    HTSE works with clients on batch and continuous process control projects ranging from single loop to plant-wide systems. We deliver solutions using the best available standard systems and components. Whenever possible, we design DCS, PLC, and PC based control solutions using widely marketed hardware and SCADA platforms. Such systems ensure better vendor support and spare parts availability and allow HTSE systems to be supported by you in-house, by us, or through other providers in addition to HTSE.

    The control of a batch or continuous process demands a specific knowledge of process automation. Knowledge of standards like S88 and significant experience are a necessity in the successful implementation of a batch or continuous process control system. HTSE possesses the in-house expertise to answer questions such as:


    • What are the best proven methodologies and available technologies to meet the need?
    • How should the process be segmented?
    • What is the best way to standardize batch building blocks i.e. chemical additions, etc.?
    • How should recipes be constructed?
    • What about FDA and regulatory compliance?
    • Does the process design meet the specific automation standards?
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    Channel Partner

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    HTSE can work with you to determine your control system and total process automation needs. We can perform on-site reviews, prepare written plans, estimate and propose a complete solution. HTSE has the experience and know-how to implement your process control utilizing many vendor platforms.

    Start-up, Troubleshooting, and Commissioning Services
    HTSE engineering staff has the field skills and experience necessary to support the start-up and commissioning of your automated processes and machinery. We offer training and system documentation services so that your plant personnel can operate and maintain the systems we design and install. As an automation service provider, our responsibility is to provide a robust, reliable and profitable system for our clients. We will:

    • Develop start-up and commissioning documents and/or checklists for equipment and controls
    • Work with the trades on power-up to check field devices
    • Operate each piece of equipment or portion of the process to observe, identify, and correct problems
    • Confirm all communications are functioning properly
    • Provide all PLC program or DCS configuration testing and debug
    • Tune control loops
    • Perform fault annunciations and alarm action verification testing
    • Perform process and/or equipment operational verification
    • Finalize and verify that the requirements of the design are satisfied
    • Perform or be present for dry and production runs
    • Perform validation execution or other regulatory checks if required
    • Provide operator training
    • Provide operations manuals
  • Machine Control

    Machine Control

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    HTSE possesses industry leading experience in the automation and commissioning of packaging lines and manufacturing equipment. We have successfully completed hundreds of client manufacturing line projects in the pharmaceutical, food & beverage, consumer product, and manufacturing sectors.

    We have extensive automation expertise in the areas of:
    • Packaging lines
    • Vision systems, RFID, and barcode verification
    • PLC programming - machine level and line control
    • HMI/SCADA - machine level and line control
    • Pharmaceutical validation documentation and execution
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    From pharmaceuticals and infant formulas to cereals and candy, HTSE has the requisite knowledge and experience in the control of manufacturing equipment and packaging lines. HTSE can provide packaging and machine control solutions that reduce product variation, waste and line downtime.

    With our extensive experience in the range of pharmaceutical, food, beverage and other regulated industries, HTSE has the industry experience and engineering capabilities to provide innovative packaging line automation and machine control solutions to meet business needs. Our clients rely on our solutions wherever flexible and reliable control is needed. By maximizing line and equipment throughput and minimizing the cost of re-engineering to accommodate changes as plants grow, HTSE provides its clients with improved manufacturing performance, better yields and increased traceability.

    HTSE's portfolio includes the successful completion of hundreds of projects in the areas of:

    • Barcode and vision systems
    • Motion control
    • Sterilization tunnels, freeze dryers/lyophilizers, skid mounted process equipment
    • PLC programming - machine and line control
    • HMI/SCADA - machine and line control

    HTSE has successfully performed over 100 vision system projects consisting of more than 200 cameras for its pharmaceutical, food, beverage, and manufacturing clients. Our vision experience includes many different camera configurations from nearly every major vision system manufacturer on the market. HTSE possesses the platform know-how that is essential for the proper determination of the precise lighting and camera placement requirements that are key to the success of any vision system application.

    Start-up, Troubleshooting, and Commissioning Services
    HTSE engineering staff has the field skills and experience necessary to support the start-up and commissioning of your automated processes and machinery. We offer training and system documentation services so that your plant personnel can operate and maintain the systems we design and install. As an automation service provider, our responsibility is to provide a robust, reliable and profitable system for our clients. We will:

    • Develop start-up and commissioning documents and/or checklists for equipment and controls
    • Work with the trades on power-up to check field devices
    • Operate each piece of equipment or portion of the process to observe, identify, and correct problems
    • Confirm all communications are functioning properly
    • Provide all PLC program or DCS configuration testing and debug
    • Tune control loops
    • Perform fault annunciations and alarm action verification testing
    • Perform process and/or equipment operational verification
    • Finalize and verify that the requirements of the design are satisfied
    • Perform or be present for dry and production runs
    • Perform validation execution or other regulatory checks if required
    • Provide operator training
    • Provide operations manuals
  • Industrial Information Technology

    Industrial IT

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    IT professionals who have experience with the operational difference between industrial control networks and office networks are essential for the successful design and deployment of manufacturing-critical networks. It is what makes the difference between limping along with frustrating network problems or benefiting from a correctly designed, fully functional, and robust industrial control network that is reliable in operation.

    HTSE provides the expertise needed for the design and implementation of plant-wide or multi-site manufacturing controls networks.

    We believe it is important to develop technology solutions that address business needs, not specific technology niches. HTSE’s Industrial IT services are relevant to any industry and span all vertical markets. Our approach allows for customization and flexibility. We possess the industry experience and competence to provide our clients:

    • Technology planning and budgeting
    • Business continuity Planning and testing
    • Network design, Implementation and support
    • Network assessments
    • Technology audits
    • Hardware and software sales and support
    • Data security infrastructure Design and implementation
    • Network data assessments and testing
    • Firewall setup and configuration
    • Disaster recovery planning and testing
    • Internet communications assistance
    • Wide area network design, Implementation and support
    • Router diagnostics and maintenance
    • Remote user connectivity
    • Web enabled HMIs / web server deployment
    • Network security, VPNs and secure wireless networks
    • Environmental monitoring
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    Virtualization
    SCADA Virtualization is quickly becoming a methodology of choice for the benefits it offers in areas such as cost savings, hardware independence, and disaster recovery. Our Industrial IT engineers are experienced with the latest virtualization technologies and their application to SCADA and data acquisition systems. In addition, we have experience developing and deploying virtualization solutions in validated environments.

  • SCADA & HMI

    SCADA & HMI

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    HTSE is at the forefront of Human Machine Interfaces (HMIs) and SCADA development in industrial manufacturing applications. We have traversed the HMI's evolution from a simple push-button station replacement to advanced multi-geographic SCADA systems.

    We have developed hundreds of HMI/SCADA systems and thousands of screens utilizing numerous platforms on nearly every type of user interface. HTSE realizes the value of a well thought-out HMI/SCADA system and its ability to help individuals predict, troubleshoot, and diagnose process problems. We develop HMIs with the objective of presenting the user with information that is readily accessible, consistent, and understandable. Regardless of the HMI manufacturer, our development concept is consistent; we design a system that is reliable, structured, standardized, and flexible. Our diverse HMI / SCADA experience has exposed HTSE design engineering staff to countless platforms and best practice configurations. In all, we understand the challenges that developing an effective and functional HMI can present.

    Virtualization
    SCADA Virtualization is quickly becoming a methodology of choice for the benefits it offers in areas such as cost savings, hardware independence, and disaster recovery. Our Industrial IT engineers are experienced with the latest virtualization technologies and their application to SCADA, reporting, and data acquisition systems. In addition, we have experience developing and deploying virtualization solutions in validated environments.

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  • Reporting

    Reporting

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    HTSE can integrate factory floor data with MES, MRP, and ERP systems. We understand the importance of integrating factory floor data into upper-level planning systems in a timely and reliable fashion. Our engineers have extensive knowledge of both historical and real time process data gathering and can migrate this data into industry standard database and reporting systems. HTSE has the experience and know-how to implement your recipe, statistical process control, alarm history, and downtime tracking systems. We have experience with the following platforms:

    • AspenTech
    • GE Proficy
    • OSIsoft OSI-PI
    • Rockwell Automation
    • Wonderware
    VMware Partner Professional Solution Provider logo
    Virtualization
    Server Virtualization has become the methodology of choice for the benefits it offers in areas such as cost savings, hardware independence, and disaster recovery. Our Industrial IT engineers are experienced with the latest virtualization technologies and their application in reporting and data acquisition systems. In addition, we have experience developing and deploying virtualization solutions in validated environments.
  • Validation

    Validation

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    HTSE provides validation solutions for life science and other regulated companies. We possess extensive knowledge and experience in the validation of medical device, pharmaceutical processes, and packaging line control systems. We have experienced staff that can lead and execute validation projects and maintains a thorough understanding of regulatory compliance requirements for regulated industries. We understand the deliverables of a validation project and have the requisite experience required for the development and execution of:

    • ASTM validation
    • CV - Computer Validation
    • VMP - Validation Master Plans
    • UR - User Requirements
    • FS - Functional Specifications
    • DD - Design Documents
    • FAT - Factory Acceptance Tests
    • IA - Impact Assessments
    • IQ - Installation Qualifications
    • OQ - Operational Qualifications
    • PQ - Performance Qualifications
    • CSV - Computer Systems Validation
    • DR - Disaster Recovery Procedures
    • SOP Development
    • Controls / Automation Qualifications

    HTSE offers proven successful project methodologies that comply with Current Good Manufacturing Processes (cGMP). We possess a broad spectrum of validation experience to qualify your systems and equipment.

Platforms

Exceptional performance requires exceptional capability.

Although HTSE maintains vendor independence, we have partnerships with key platform and component providers - as well as extensive experience in the development and deployment of solutions using their technologies. In addition, we have substantial experience with many other industry standard (...and not so standard) control applications. We have gained a broad exposure to a very diverse set of control platforms and systems.


In the world of process automation and machine control, the state-of-the-art changes continuously. The winning formula for keeping up is platform training + related experience. We institute continuing employee education and training programs. This ensures our staff is not only experienced in the support of legacy systems, but also knowledgeable and skilled in the design and deployment of emerging control platforms and technologies.

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Systech VAR & Select Service Provider

Cognex

DataMan, In-Sight, VisionPro

Datalogic

DataVS2, P/A/T, MX / MX-U Series

Keyence

CV-X100/X200, CV Series, XG Series

Systech

TIPS, UniSeries

and others…

Markets

At HTSE, our strategic driver is to maintain both a strong market focus and product focus which translates into decreased project timelines, more reliable system performance, and ultimately, higher manufacturing throughput for our clients. This creates client satisfaction which is key to the building of a strong long-term client relationship.

Repeat business is the result of a strong long-term client relationship and is a true testament of track record - in fact, it accounts for 90% of our work.

With over 1000 completed projects for client corporations; our clients know us for our depth of knowledge, economy of use, and skillful project executions. Regardless of project size, we take a partner’s interest, investing our knowledge and energy as stakeholders.

  • Chemical

    Chemical

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    Safety systems, reliable plant operation, adherence to regulations and environmental laws are just some of the many factors that add automation challenges to requirements in the chemical industry. These issues make it all the more important to have a competent partner who is not only familiar with the specific requirements for equipment and industrial systems, but also has a sound understanding of the process engineering procedures and specific requirements in the chemical industry. HTSE provides automation and project support services for chemical manufacturers. We have extensive experience in the control of chemical manufacturing processes and equipment using robust DCS and PLC control technologies and associated operator interfaces. We posses a thorough understanding of the requirement for rugged and dependable controls along with the process safety systems associated with chemical manufacturing and control.

    Our automation experience for chemical manufacturers includes:

    • Pressure, temperature, and flow control
    • Batching control systems
    • Continuous control systems
    • Fired equipment
    • Reactor control
    • SIL - Safety Instrumented Systems
    • Mixing & blending
    • Process manufacturing equipments i.e. tank farms, heat exchangers, fluidizing beds, transporters, distillation columns, dryers, etc.
    • Utilities i.e. steam, compressed air, etc.
    • Water systems

    chemical mixing in beaker
  • Pharmaceutical

    Pharmaceutical

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    HTSE provides automation and validation solutions to some of the world’s largest pharmaceutical companies. We possess extensive knowledge and experience in the automation and validation of pharmaceutical process and packaging line control systems and a thorough understanding of regulatory compliance requirements. We have experienced engineering staff who can lead and execute pharmaceutical projects. Our pharmaceutical portfolio includes the successful completion of hundreds of projects in the areas of:

    Packaging Lines
    • Powder and liquid fillers, cartoners, checkweigh systems, collators, bundlers, labelers, casepackers, sorters, palletizers, packaging line integration
    • Barcode and vision systems
    • Motion control
    • PLC programming – machine and line control
    • HMI – SCADA and machine and line control
    • Environmental monitoring

    Process Control
    • Pressure, temperature, and flow control
    • S88 batching control systems
    • Continuous control systems
    • HVAC controls
    • Process manufacturing equipments i.e. tank farms, heat exchangers, fluidizing beds, transporters, dryers, etc.
    • Utilities i.e. steam, compressed air, etc.
    • Potable and purified water systems
    • Environmental monitoring
    • CIP systems
    • mixing
    • Skid control

    pharmaceutical sterile filling line

    HTSE offers proven successful project methodologies that comply with Current Good Manufacturing Processes (cGMP). We possess a broad spectrum of pharmaceutical experience to expertly control and qualify your systems and equipment.

    We understand the documentation requirements and possess full capabilities for:

    • ASTM Validation
    • CV - Computer Validation
    • VMP - Validation Master Plans
    • UR - User Requirements
    • FS - Functional Specifications
    • DD - Design Documents
    • FAT - Factory Acceptance Tests
    • IA - Impact Assessments
    • IQ - Installation Qualifications
    • OQ - Operational Qualifications
    • PQ - Performance Qualifications
    • CSV - Computer Systems Validation
    • DR - Disaster Recovery Procedures
    • SOP Development
    • Controls / Automation Qualifications
  • Food & Beverage

    Food & Beverage

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    From soft drinks and fruit juices to infant formulas, cereals and candy, HTSE has the requisite controls knowledge and experience in the manufacturing and packaging of food and beverage products. With extensive experience in food manufacturing and formulation, HTSE can provide process and packaging control solutions that reduce product variation, waste, and process downtime. HTSE has the industry experience and engineering capabilities to provide innovative automation, process, and packaging control solutions to meet your business needs. Our clients rely on our solutions wherever flexible and reliable process control is needed. By maximizing batch throughput and minimizing the cost of re-engineering to accommodate changes as plants grow or new products require manufacturing, HTSE provides food and beverage producers with improved manufacturing performance, better yields, and increased traceability.

    Our portfolio includes the successful completion of hundreds of projects in the areas of:

    • Packaging lines
    • Process control
    • Pressure, temperature, and flow control
    • Batching control systems
    • Continuous control systems
    • HVAC controls
    • Process manufacturing equipments i.e. tank farms, Exchangers, fluidizing beds, transporters, dryers, etc.
    • Utilities i.e. steam, compressed air, etc.
    • Potable and purified water systems,
    • Environmental monitoring

    HTSE offers proven successful project methodologies that comply with Current Good Manufacturing Processes (cGMP). We possess a broad spectrum of regulated industry experience to control and qualify your systems and equipment.

    process sanitary valve group
  • Medical Device

    Medical Device

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    HTSE provides automation and validation solutions for the medical device industry. From automated manufacturing cells to plant floor data acquisition, we possess a thorough understanding of regulatory compliance requirements for medical device manufacturing processes and facilities. We have medical device industry experienced engineering staff that can lead and execute validated projects. We understand the deliverables of a regulated industry project and have the requisite experience required for the development of automated manufacturing cells along with the generation and execution of:

    • ASTM Validation
    • CV - Computer Validation
    • VMP - Validation Master Plans
    • UR - User Requirements
    • FS - Functional Specifications
    • DD - Design Documents
    • FAT - Factory Acceptance Tests
    • IA - Impact Assessments
    • IQ - Installation Qualifications
    • OQ - Operational Qualification
    • PQ - Performance Qualifications
    • DR - Disaster Recovery Procedures
    • CSV - Computer Systems Validation
    • SOP Development
    • Controls / Automation Qualifications

    surgical saw

    HTSE offers proven successful project methodologies that comply with Current Good Manufacturing Processes (cGMP). We possess a broad spectrum of regulated industry experience to control and qualify your systems and equipment.

  • General Manufacturing

    General Manufacturing

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    Since 1989, HTSE has supported numerous and diverse manufacturing clients. While each client's project is unique in its specific challenges, HTSE has the industry experience and capabilities to provide innovative automation solutions to meet those challenges.

    Clients rely on us for solutions that maximize throughput, lower operational costs, and minimize the cost of re-engineering to accommodate changes as their facilities grow.

    Our automation experience for consumer products manufacturers includes:

    • Controls design
    • PLC, DCS, and HMI application development
    • Industrial IT network design and deployment
    • Data acquisition, reporting and presentation

    HTSE offers proven successful project methodologies that comply with Current Good Manufacturing Processes (cGMP). We possess a strong spectrum of regulated industry experience to control and qualify your systems and equipment.

    manufactured tools
  • Consumer Products

    Consumer Products

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    Since 1989, HTSE has supported numerous and diverse manufacturing clients. While each client's project is unique in its specific challenges, HTSE has the industry experience and capabilities to provide innovative automation solutions to meet those challenges.

    Our clients rely on us for solutions that maximize throughput, lower operational costs, and minimize the cost of re-engineering to accommodate changes as their facilities grow. Our automation experience for consumer products manufacturers includes:

    • Controls design
    • PLC, DCS, and HMI application development
    • Industrial IT network design and deployment
    • Data acquisition, reporting and presentation
    • Bid packages and project management services
    • CAD Services

    HTSE offers proven successful project methodologies that comply with Current Good Manufacturing Processes (cGMP). We possess a strong spectrum of regulated industry experience to control and qualify your systems and equipment.

    automated manufacturing line

Company

We know the key to any successful project is communication. Please feel free to contact us anytime; we are here to answer your questions and welcome any ideas or feedback. Thank you for visiting htse.com.