Black Controls successfully completed its second Gamma Irradiation Controls Upgrade project. The existing system had been in operation for over 20 years and required modernization to improve reliability, product tracking, and compliance with current safety standards. Here’s how we delivered a fully upgraded, high-performance control system.
Initial Investigation
Our team began with an on-site assessment to evaluate the current system’s functionality, performance, and limitations. Working closely with the customer, we conducted a detailed process review and defined the upgrade requirements to align with their operational goals and safety compliance needs.
Industrial control panel assembly with SIEMENS S7-1500 Safety PLC
SIEMENS G120 Variable Frequency Drives (VFD’s) and SIEMENS contactors for motor control
Design
Once the project scope and timeline were approved, we initiated our internal design phase. This included:
Our design ensured both enhanced system functionality and strict adherence to international safety standards.
Manufacturing
Following design approval, we manufactured:
Initial control panel commissioning was conducted at our facility before shipping, this allowed for efficient validation during the installation at the site.
SICK safety light curtains with muting sensors for product entry into hazardous radiation zones
Penthouse industrial control panel with SIEMENS IM PLC rack and contactors
Shipping & Installation
All components were securely packaged and shipped via ocean freight to the customer’s facility in Southeast Asia. Our team completed the installation during a scheduled production shutdown, minimizing disruption and downtime. We then supported the customer through system validation to ensure readiness for full production.
System Qualification
To ensure system performance, safety, and regulatory compliance, we followed a structured qualification process.
Installation Qualification (IQ)
Verified that equipment and ancillary systems were installed per specifications, including:
Installation of new motor and controls wiring into our new industrial control panels
Field wiring for sensing and ROSS redundant safety pneumatic dump valve
Operational Qualification (OQ)
Confirmed that the system operates within defined control limits, including:
The Result
A modern, validated control system—engineered for long-term reliability, improved performance, and full compliance with today’s safety standards.
Warehouse industrial control panel with SIEMENS IM PLC rack, G120 VFD’s and contactors
Field wiring and controls utilizing SIEMENS emergency stop and HUBBELL motor disconnects
Field wiring and controls utilizing SMC pneumatic valve bank, MURR ELEKTRONIC Cube67 fieldbus