Automate Your System with Customized Control Solutions

All Flexicon equipment and systems are available with programmable logic controllers (PLCs) and human-machine interfaces (HMIs) to ensure maximum equipment productivity while meeting your process requirements.

Integrated Controls Capabilities

The Flexicon Controls and Automation Department combines state-of-the-art control technologies with our full-scale fabrication capabilities by specifying, engineering, fabricating and testing control systems to maximize equipment productivity while meeting customer requirements.

Hardware

  • At the core of every controls package, whether powering a simple conveyor or managing a complex plant-wide process system, Flexicon utilizes advanced programmable logic controllers (PLCs) engineered for precision, reliability, and scalability. 
  • User-friendly interfaces, ranging from simple push buttons to advanced touch screen HMIs with intuitive graphics, are fully customized to your application. Designed with High Performance HMI principles and a strategic color philosophy, these interfaces enhance operator awareness, reduce response time, and ensure safe, efficient system control.

Programming

  • PLC programming capabilities facilitate customized industrial processes with advanced features like precision weight reporting, custom recipe storage, critical notifications, intuitive messages, customer defined parameters, login credentials and seamless machine interfacing. 
  • Communication is developed and supported at every level, from basic start/stop control and run permissives, to advanced fault reporting, recipe management, and system coordination across your entire plant network. 
  • PLC programs are written with clean, organized and documented logic, designed for easy troubleshooting, comprehension and future expansion.

Design Construction

  • Control panels are custom-built to your exact specifications and engineered following industry best practices to ensure reliability, safety, and scalability. Each panel includes detailed schematics, wire labels, and comprehensive component documentation to provide clear guidance and simplify maintenance.
  • Building control panels in-house ensures full quality control, precise customization, faster turnaround, cost efficiency, thorough documentation, and simpler implementation of changes.

Testing

  • Each control panel undergoes 100% bench testing to verify proper control functionality before shipment. We simulate real-world process conditions using actual inputs and outputs such as scale systems, various sensor types, and electric motors to thoroughly test control logic, safety interlocks, and operational sequences. 
  • Whether it’s a basic start/stop system or a complex multi-step batch process, every panel is evaluated to ensure safe, reliable performance and is delivered meeting all specified requirements and ready for immediate production use.
  • The testing process involves simulating worst-case scenarios such as an operator pressing incorrect buttons in various sequences and combinations to identify system vulnerabilities and ensure robust error handling.

Certification

  • UL Listed NEMA 4 and 4X control panels
  • UL Listed NEMA 7/9 and Z/X purged control panels available upon request
  • CSA/cUL approved control panels available upon request
  • UL 508a certified control panel shop

Our Automation Benefits

Enhance your Flexicon equipment with custom controls solutions to increase automation and boost operational efficiency within your bulk handling process.

Remote Support and Troubleshooting

Flexicon engineers have secure remote access capabilities, allowing them to connect to your plant’s control systems for ongoing support, performance optimization, and system updates.

Scalability

As your needs and/or your systems change, Flexicon control systems can be fine-tuned or reprogrammed to meet processing line expansion, new equipment and new applications requirements.

System Integration

A Flexicon Programmable Logic Control System can manage the operation of a complex industrial process including multiple pieces of equipment operating simultaneously, regardless of the manufacturer, along with supporting communication and data exchange.

Security

A tiered system of permissions enables protection of proprietary information and system functionality, while allowing others limited access to data required to perform routine processes.

Complete Documentation

Every control system includes clear, detailed documentation to support installation, operation, and long-term maintenance. This documentation facilitates efficient troubleshooting, operator training, and future system expansion by providing comprehensive technical guidance and operational clarity.

Automation & Controls Advanced Features

Flexicon provides customized controls and automation services, utilizing cutting-edge programming techniques and premium hardware to meet your unique needs, with a range of available features.

Integration

Flexicon’s systems communicate effortlessly with your existing equipment and can integrate other vendors’ machinery, including mixers, packaging lines, and other process equipment. This flexibility ensures all components of your production process work together, enabling a streamlined workflow and keeping your facility running at peak performance while supporting future upgrades and expansions.

Weigh Batching

Flexicon’s weigh batching systems deliver precise, reliable batching for single or multi-ingredient processes, from stand-alone units to plant-wide control. Recipe management reduces errors and material waste, while improving batch quality and operational efficiency. Engineered for seamless integration and scalable growth, our solutions help you produce consistent, high-quality batches every time and keep your operation running smoothly.

Remote Support Capabilities

We provide industrial-grade VPN routers that let our engineers connect securely to your control systems without compromising safety or network integrity. Advanced VPN security ensures all remote sessions are fully encrypted, while our team can monitor, diagnose, and support your PLC systems in real time. These routers come pre-configured for industrial environments, making setup simple with minimal customer IT support. Access is strictly controlled, allowing only authorized personnel to connect, keeping your network safe. You receive expert remote support that is accessible, reliable and secure helping your operations run smoothly without exposing your network to risk.

High Performance HMI

Our operator interfaces are designed using High-Performance HMI principles to maximize efficiency, safety, and situational awareness. By delivering clear, intuitive displays, responsive feedback, and meaningful data visualization, our solutions reduce errors and streamline operations. These interfaces help your facility stay productive and empower your team to make faster, smarter decisions.

Additional Features

  • In-House Custom Panel Shop 
  • Custom Graphics
  • Safety Circuits
  • Label Printing
  • Batch Recording
  • Bar Code Scanning

Bulk handling test lab equipment

Flexicon meets the process control requirements for areas zoned as explosion hazards. Our controls provide worker and facility safety measures while delivering optimal equipment performance.

  • Enclosures meet NEMA 7/9 or ATEX Zone 20, 21, or 22 ratings
  • Explosion-proof aluminum panels prevent internal explosions and spark ignition
  • Local-rated operator panels connect to motor control cabinets in safe areas via intrinsic safety barriers
  • Nitrogen or compressed air-purged panels block fumes and dust, with sensors, alarms, and automatic shut-off for failures
  • Labeling and engraving services provide essential instructions and warnings on control panels

Automation for Large Scale Bulk Handling Systems

Flexicon’s Project Engineering Division (PED) focuses exclusively on large-scale bulk handling systems, delivering comprehensive automation solutions for integrated systems. Our multi-disciplinary team integrates a wide variety of process equipment from multiple manufacturers, ensuring compatibility and performance across the entire system. By taking full responsibility for your project, PED removes the complexity and uncertainty of managing multiple suppliers. For high-impact initiatives, our dedicated project team brings the expertise and oversight needed to drive success from planning through execution.

Any bulk material challenge, handled.