iconsys
Modernising Kiln Control Systems with Siemens Technology, iconsys Engineering, and Parmley Graham Supply Partnership
iconsys is a platform-independent provider of integrated automation solutions. It has the combined knowledge, innovation and commitment to enhance performance across multiple industries.
Overview
Why the need?
Faced with an ageing and unsupported kiln control system, a UK-based industrial customer partnered with iconsys, Siemens, and Parmley Graham to deliver a modern, reliable, and future-ready automation solution. This collaboration led to a significant improvement in usability, performance, and operational resilience.
Background
Kiln operations demand precise and dependable control. The customer’s legacy system, based on Cellatronic and Cellacontrol technology, was increasingly difficult to maintain, lacked UK support, and posed a serious risk of downtime and inefficiency.
The challenge was to replace the obsolete front-end control system while retaining the existing temperature controllers and burner management units. The new solution needed to improve:
- Recipe selection and data entry speed.
- System diagnostics and error reporting.
- Data logging and trending capabilities.
- Operator usability and safety compliance.
Project Challenges:
The legacy system included:
- Two Cellatronic controllers for kiln pushing and master zone temperature control.
- Cellacontrol interface, requiring manual programming via keyboard.
- Multiple zone-based Cellatronic temperature controllers, linked to burner management units.
Key issues:
- Obsolescence: No UK support and limited technical documentation.
- Poor user experience: Manual keyboard input was slow and unintuitive.
- Slow communication: Data exchange between controllers was sluggish.
- Operational risk: Ageing hardware made diagnostics and troubleshooting difficult.
Solution Impact
iconsys led the engineering design and implementation, supported by Siemens technology and Parmley Graham’s hardware supply expertise.
- Hardware Modernisation
- Parmley Graham supplied a Siemens PLC system, replacing the outdated Cellatronic controllers.
- Control functions were consolidated into a single, secure, and reliable platform.
- SCADA Integration
- The Cellacontrol system was replaced with a desktop PC running Siemens WinCC Professional SCADA.
Features included:
- The Cellacontrol system was replaced with a desktop PC running Siemens WinCC Professional SCADA.
- Real-time HMI displays.
- Advanced data logging and trending.
- Visual error diagnostics.
- Functional Enhancements
- Secure remote access to the SCADA server.
- Safe recovery from power surges/dips.
- Controlled entry system with interlocks for safety compliance.
- Full system documentation and operator training.
Benefits Delivered
- Enhanced Usability
- Operators now use an intuitive interface with clear process visualisation, simplifying recipe input and alarm response.
- Faster and More Reliable Operations
- Improved speed in recipe selection and diagnostics has boosted production throughput and reduced wasted time.
- Improved Safety and Compliance
- The system meets modern safety standards with interlocks, access control, and safe shutdown/recovery features.
- Future-Proof Technology
- Built on Siemens PLC and SCADA, the system is scalable, resilient, and supported long-term.
- Reduced Downtime
- Clear HMI error states and remote access enable faster fault diagnosis and support, minimising production losses.
Services Provided
- Project management and engineering design.
- Siemens PLC upgrade (supplied by Parmley Graham).
- Safety I/O implementation
- WinCC Professional SCADA development.
- Commissioning, operator training, and ongoing support.
Outcome
The customer now benefits from a kiln control system that is:
- Robust – built for demanding industrial environments.
- User-friendly – with intuitive operation and remote access.
- Compliant – aligned with current safety standards
- Future-ready – scalable and supported by Siemens technology.
This project highlights the power of collaboration between systems integrators, technology providers, and supply partners in delivering transformative industrial automation solutions.
“This project was about more than just replacing obsolete equipment – it was about giving the customer a control system that is modern, intuitive, and resilient for the future. By combining Siemens’ technology with Parmley Graham’s supply expertise, we were able to deliver a solution that not only met today’s requirements but also provides a secure and scalable foundation for years to come.”
“Our role was to ensure iconsys had fast and reliable access to the Siemens hardware needed for this upgrade. By working closely with both Siemens and iconsys, we were able to streamline supply and ensure the right technology was in place at the right time. It’s a great example of how strong partnerships can deliver real value to the end customer.”
Get in Touch
To discuss how the PG team can help your business, either email us at support@parmley-graham.co.uk or call 0191 478 0404.
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