Solutions

Four Ways We Keep Your Equipment Running

We work on the control layer, not the machine itself. That means lower cost, faster timelines, and no disruption to what’s already working mechanically.

Solution 01

CNC Controller Modernization

A CNC machine with a working spindle and intact mechanics can last another 20 years. The controller is what fails first. We replace it with an open, maintainable system that runs modern G-code and connects to your network — without touching the machine tool itself.

  • Fanuc, Mitsubishi, Mazak, and proprietary controller replacement
  • LinuxCNC or equivalent open-source controller installation
  • Existing servo drives, spindles, and tooling preserved
  • G-code library migration and documentation
  • Operator training and full wiring documentation
  • Network-ready with optional air-gap for secure environments
Get a CNC Assessment →

Before & After

Fanuc Series 6 ControllerReplaced
↓ modernized to
LinuxCNC 2.9 (open-source)Active
+20yr
Equipment Life Added
~80%
Cost vs. New Machine
100%
G-Code Compatibility
2–5d
Typical Downtime

Solution 02

Municipal Water & Wastewater SCADA

Water and wastewater treatment systems are critical infrastructure that often run on 20-year-old SCADA platforms with no security architecture, single points of failure, and zero documentation. We modernize them safely, with full air-gap capability where required.

  • Legacy SCADA replacement with hardened open-source platform
  • OT/IT network separation with physical data diodes
  • Full air-gap option for high-security or rural utilities
  • Redundant local historian and alarm management
  • Regulatory compliance documentation
  • Disaster recovery runbooks for non-technical operators
Request a Site Assessment →
Water Plant SCADA Monitor

# Plant status — 16 Jul 2025 08:42

Flow rate: 4.2 MGD [normal]

Chlorine residual: 0.8 ppm [OK]

Pump 1: RUNNING

Pump 2: STANDBY

Network: AIR-GAPPED

 

# Last backup: 08:30 (local only)

# External connections: NONE

Status: ALL CLEAR ✓

Solution 03

PLC & HMI Upgrades

Cracked touchscreens, obsolete PLCs, and paper-based operator interfaces create risk every shift. We replace the interface layer without rewriting your control logic from scratch — operators keep the process they know, on hardware that’s supportable.

  • Allen-Bradley, Siemens, Modicon PLC migration
  • Modern touchscreen HMI with process-matched interface design
  • Ladder logic documentation and code review
  • Alarm logging and historical trend viewing
  • Remote monitoring option (with proper OT/IT separation)
  • Operator training included in every engagement
Discuss Your PLC Situation →

Compatible Platforms

Allen-Bradley SLC 500 / PLC-5Supported
Siemens S5 / S7 SeriesSupported
Modicon 984 / QuantumSupported
GE Series 90Supported
Other legacy PLCsAsk Us

Solution 04

Industrial AI Documentation

The most dangerous thing in most manufacturing and utility operations isn’t a machine failure — it’s the retirement of the person who knows how everything works. We capture that knowledge before it walks out the door and put it in a searchable, AI-powered system that runs entirely on your premises.

  • Structured operator knowledge interviews and capture sessions
  • Extraction and digitization of paper-based documentation
  • AI-searchable knowledge base (on-premises, no cloud)
  • Machine-specific troubleshooting guides and fault libraries
  • G-code and program parameter backup with version control
  • Paired with Cloud-Free-AI SCIF vault for maximum security
Start a Knowledge Capture Project →
Industrial Knowledge Vault — Floor 2

QUERY

“Why does spindle fault E042 appear on cold starts?”

AI ANSWER — from operator notes, 2019

“E042 on cold start indicates spindle bearing grease hardening below 50°F. Run spindle at 200 RPM for 3 min before production. See maintenance note MN-114.”

All data local · No internet required · Source cited

Not Sure Where to Start?

Schedule a Free On-Site Assessment

We visit your facility, evaluate your equipment, security posture, and documentation gaps, and deliver a prioritized action plan. No obligation, no pitch.

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