Controls Upgrade

Client: Confidential
Location: East Coast U.S.


Burns & McDonnell designed and installed motor control center (MCC) and programmable logic controller (PLC) upgrades in a coffee plant. Obsolete relay and PLC control systems for coffee transfer process equipment, roasters and flavor mixing systems were replaced. Our team installed new Wonderware HMI server and HMI terminals. We removed existing process control/MCC panel, established control standards, and implemented new equipment numbering and labeling.

Project Scope

  • Installed three Allen-Bradley Smart MCCs
  • Upgraded existing Allen-Bradley PLC-5 and relay controls with Allen-Bradley ControlLogix PLCs
  • Implemented Allen-Bradley Flex I/O in process areas for distributed I/O system
  • Installed new Wonderware system platform HMI server and thin-client HMI panels for visualization
  • Developed PLC and HMI templates to be used as plant controls standards 
  • Provided startup and commissioning support
  • Conducted onsite training for plant personnel

Project Successes

  • Improved troubleshooting capabilities via HMI graphics
  • Developed plant controls standards
  • Improved electrical wiring documentation and plant equipment and device labeling
  • Managed construction with minimal impact on production due to careful phasing and working closely with the plant's production scheduler
  • Provided 24/7 construction and startup support
  • Completed project on schedule and on budget


  • Preliminary engineering
  • Detailed design
  • Procurement
  • Construction
  • Startup and commissioning