Kiln and dryer control modernisation
Upgrade of legacy control hardware and operator interfaces with improved process visibility and alarm management.
Industry · 07
Building Products
Building products automation for bricks, tiles, pavers and heavy clay manufacturing with precise process control and reliable uptime.
We have engineered automation projects for building products manufacturers including Austral Bricks, one of Australia's largest brick manufacturers. The work covers brick, tile, paver and heavy clay lines, from targeted control upgrades through to broader modernisation programs.
Kilns, dryers and material handling systems run continuously and consume significant energy. Better process visibility means better control of both throughput and utility consumption. We integrate production and utility data so operations teams can make decisions based on what is actually happening on the line, not what was happening last shift.
What's tough
Problems we solve
01
Continuous process stability
Dryers, kilns and transfer systems need tightly coordinated control to maintain product quality and avoid production disruptions.
02
Legacy controls and limited diagnostics
Older systems often make fault isolation slow and increase maintenance burden during outages.
03
Energy-intensive operations
Building products sites need better visibility of process performance and utility consumption to support optimisation.
04
Safety and reliability in harsh conditions
Heat, dust and high-duty equipment place high demands on controls, electrical systems and instrumentation.
Our Approach
How we deliver
We implement modern PLC and SCADA architectures with state-based control, alarm clarity and reusable engineering standards for maintainability.
Process control strategies are designed around real operating constraints including kiln schedules, material handling sequences and dispatch requirements.
We integrate production and utility data to improve operational visibility and support energy and downtime reduction programs.
Commissioning is staged with clear test plans and fallback paths so upgrades can be delivered with controlled production risk.
Typical Work
Projects in this sector
Heavy clay material handling integration
End-to-end sequence control across feeders, conveyors, mixers and transfer points with fault-tolerant recovery logic.
Tiles and pavers line optimisation
Line-state and changeover improvements across forming, curing and packaging operations.
Production and utility analytics rollout
Data model and dashboards for throughput, downtime and utility performance across core assets.
Platforms
Technology we work with
Building products plants require control platforms that can handle continuous operations and demanding environments.
01
Rockwell and Siemens PLC/SCADA deployments for high-availability production environments.
02
Integration of drives, burners, instrumentation, weigh systems and packaging assets.
03
Industrial networking and OT architecture designed for reliability and secure support access.
04
Historian and reporting systems aligned to operations and maintenance workflows.
AS/NZS electrical and machinery safety requirements.
Documented commissioning aligned to plant acceptance criteria.
Structured alarm and control standards for maintainability.
Practical OT cybersecurity controls for industrial operations.
Common Questions
Frequently asked
Do you replace all controls at once?
Not necessarily. Most building products projects are staged to balance risk, budget and production continuity.
Can you work with existing kilns and process equipment?
Yes. We regularly integrate with existing equipment and improve control without full plant replacement.
Do you provide long-term support after commissioning?
Yes. We support ongoing optimisation, fault response and lifecycle upgrades after handover.
Ready to discuss your building products project?
Talk to an engineer who understands your industry. We'll give you a straight answer on scope, timeline, and what's involved.