Control System Design

Custom PLC & SCADA Solutions

Tailored Control System Engineering

At KDR Automation Ltd, we deliver precision-engineered control systems designed around your specific operational requirements. Our methodology follows rigorous standards from initial user requirements through to site acceptance testing.

PLC/SCADA Control System

We deliver robust industrial automation solutions through customized PLC and SCADA systems tailored to your operational requirements including:

  • Custom PLC programming, experienced in Siemens, Mitsubishi and other client specific platforms
  • SCADA system design and advanced HMI development for real-time monitoring and control
  • Industrial communication network configuration (ProfiNET, Ethernet/IP, Modbus)
  • Full system integration with existing equipment and enterprise systems
  • Alarm management and historical data logging implementation
  • Documentation including functional design specifications and O&M manuals

Modular Code Development

We implement industry-best coding practices:

  • Object-oriented programming (IEC 61131-3)
  • Version control
  • Standardised naming conventions
  • Comprehensive code documentation
  • Robust code review and testing protocols

Simulation & Testing

Rigorous verification before deployment:

  • Virtual commissioning with digital twins
  • Factory Acceptance Testing (FAT) protocols
  • Exception handling validation
  • Performance benchmarking

GAMP-Compliant Design

Our design process follows Good Automated Manufacturing Practice (GAMP 5) guidelines:

  • Category 4/5 software validation approach
  • Traceability matrix linking requirements to design
  • Modular architecture for future expansion
  • Cybersecurity-by-design principles
Tailored Control System Engineering service

Our System Design Capabilities

URS Development

Comprehensive requirement documentation

Functional Design

Detailed control strategy specifications

Modular Coding

Scalable, maintainable program architecture

FAT/SAT Execution

Formal verification and validation

Change Management

Controlled modification processes

Data Historians

Trending and reporting solutions

Brands

Siemens logo representing Siemens industrial automation and digitalization solutions, including SIMATIC PLCs (S7-1200, S7-1500, S7-200, S7-300, ET 200SP), PROFINET/PROFIBUS/OPC UA networks, WinCC HMIs (Comfort, Unified, Advanced), WinCC Professional/OA SCADA systems, and TIA Portal with SIMATIC STEP 7 for integrated engineering and diital twin integration.
Mitsubishi Electric logo for industrial automation, featuring MELSEC PLCs (Q-Series, iQ-R, iQ-F, FX1/2/3/5), SSCNET servo systems, GOT1000/2000 HMIs, CC-Link IE Field network integration, GX Works programming software, and safety controllers (QSCPU).
Ignition SCADA logo representing Ignition by Inductive Automation, a scalable SCADA and IIoT platform for industrial automation. Features include real-time monitoring, data visualization, MQTT and OPC UA connectivity, edge computing, and web-based deployment for seamless control and analytics.
SICK logo representing SICK industrial safety solutions, including FlexiSoft safety PLCs, safety light curtains, safety laser scanners, and advanced machine safety systems for industrial automation and workplace protection.
RDM (Resource Data Management) logo representing integrated building automation and refrigeration solutions, including RDM Intuitive V2 and Data Manager for data monitoring, Building Management Systems (BMS), IoT-enabled refrigeration controllers, BACnet, MODBUS, energy optimisation, and cloud-based facility management platforms.
Loxone logo representing Loxone smart home and building automation solutions, including Loxone Miniservers for intelligent control of lighting, climate, security, and energy management. Features KNX, Modbus, and DALI compatibility, predictive heating algorithms, and decentralized automation for scalable residential to commercial applications. Integrates seamlessly via the Loxone App, Touch Panels, and voice assistants (Alexa, Google Assistant, Siri).
ABB logo representing ABB Robotics' industrial automation solutions, including ABB industrial robots (IRB series like IRB 2600, IRB 6700), collaborative robots (YuMi, GoFa), and robot controllers (OmniCore, IRC5) programmed with RobotStudio simulation software. Features TrueMove and QuickMove motion control, Machine Vision integration, SafeMove safety technology (ISO 10218 compliant), and end-effector customization for welding torches, grippers and specialized tooling. Supports Industry 4.0 standards (OPC UA, Ethernet/IP) for welding, material handling, and assembly applications across automotive, electronics, food & beverage, and logistics industries.
Omron logo representing Omron industrial automation products, including Omron PLCs (CP Series, CJ Series, CS Series, NX Series, and NJ Series), Omron HMIs (NB Series, NS Series, NA Series), and Omron industrial networks such as EtherCAT and EtherNet/IP, designed for advanced automation and machine control.

Need a compliant, future-proof control system?

Discuss Your Project

Frequently Asked Questions

What's your approach to legacy system upgrades?

We follow a phased migration strategy with parallel running to ensure continuity, starting with risk assessment and ending with full validation.

How do you ensure code maintainability?

We implement modular code structures with comprehensive documentation, version control, and standardized naming conventions.

What industries require GAMP compliance?

Primarily pharmaceutical, medical devices, and food production where product quality and patient safety are regulated.

Do you provide ongoing support after SAT?

Yes, we offer tiered support packages including on-call assistance, periodic reviews, and change management services.

How do you handle cybersecurity in control systems?

We implement defense-in-depth strategies including network segmentation, role-based access, and regular vulnerability assessments.

What validation documents do you provide with automation projects?

We deliver full UKCA/CE-compliant documentation packages including Functional Design Specifications (FDS), Factory Acceptance Test protocols, and traceability matrices - all tailored to your industry requirements.

How do you ensure design compliance?

Our Design Review (DR) process and Hardware/Software Design Specifications (HDS/SDS) are developed in accordance with IEC 61508 and Machinery Directive 2006/42/EC, with audit-ready documentation at every stage.

What's included in your operational documentation?

Every project includes an Operation & Maintenance Manual (OMM), configuration specifications, and critical spare parts lists to ensure long-term system reliability and simplified maintenance.

How are acceptance tests conducted?

We perform rigorous Factory Acceptance Testing (FAT) at our facilities followed by Site Acceptance Testing (SAT), with both processes fully documented and aligned with your quality protocols.

Do you provide training documentation?

Yes, we supply structured operator training materials and competency checklists as part of our handover package, ensuring your team achieves full system proficiency.

How do you handle design changes during projects?

All modifications are tracked through our revision-controlled Configuration Specifications (CS) and updated traceability matrices, maintaining complete audit trails throughout the project lifecycle.

Our Other Services

Industrial Automation Solutions
Control System Design
Robotic Integration Services
Machine Safety Systems
Process Optimisation
Maintenance & Support