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Process Automation

Today’s economic pressures have greatly affected performance and growth in industries utilizing process automation. Uncertainties regarding the current recession, fluctuating oil prices, globalization and political forces are limiting manufacturers’ ability to invest in new plants and process automation technologies. Limited investment capital means that you can only undertake the process automation projects with the shortest potential payback periods.

A plant’s process automation technologies, control systems and supporting data and infrastructure offer the greatest potential leverage for improving productivity and profits. When properly designed and engineered, process automation solutions provide the opportunity to increase production rates, improve yields and reduce energy consumption.

MAVERICK Technologies has the process automation experience and expertise needed to optimize the investment in your control systems and data infrastructure. Our proven capabilities enable us to look at your entire operation from a complete business perspective — from the plant floor to the boardroom — to maximize your total investment and return on capital expenditures. We deliver process automation solutions for major players across a range of industries worldwide, achieving governmental compliance while reducing environmental impacts on your personnel and the community. Leverage our vast process automation experience to your advantage, realizing executable solutions for all your challenges.

Process Automation and Control

Process automation and control is at the core of MAVERICK’s business. MAVERICK has experience working with every major DCS and PLC available in the marketplace today, enabling I/O optimization. We leverage your existing infrastructure to implement process automation solutions designed for your manufacturing and processing needs. Our process automation expertise spans all manufacturing industries, including oil and gas (upstream and downstream), chemical and petrochemical processing, pharmaceutical, and power and utilities.

Business Process

MAVERICK’s business systems and operational consultants analyze your business processes and provide actionable insights for streamlining the flow of business information to realize measurable benefits. The key to success lies in the combination of people, processes and technology. We work with you to ensure that the requirements for your targeted process automation technology implementation produce the desired results — from the plant floor to the boardroom — and that the business and operational processes are in place to support the implementation.

Data Management and Historian

Collecting, storing and distributing real-time production data as part of process automation allows plants to identify the causes of operational problems and quality issues. MAVERICK works with its clients to implement data management systems and historians as part of continuous improvement with initiatives, helping managers use these tools to analyze their production data and make smarter decisions for increased productivity, quality and compliance.

Business Continuity and Disaster Recovery

Business continuity and disaster recovery (BC / DR) refers to the process of bringing a plant or business back online following a disaster, and how to manage the operation of the business in light of new challenges that may exist. A natural disaster would cause problems such as damage to facilities, diminished availability of power and utilities, supply chain and transportation problems, and reduced staff. A large-scale cyber attack would yield different destructive results, which may include damage to plant equipment and facility management operation. Catastrophic loss of data, servers, process automation technologies and network infrastructure are also highly likely.

Whether you are recovering from a fire, explosion, hurricane or other disaster, MAVERICK is there for you. We understand that it can be a while before you will be able to focus on your discrete process control areas. After caring for your personnel, your first concerns will most likely include the reestablishment of your infrastructure and stabilization of your equipment and process automation technologies.

MAVERICK’s team of business solution consultants, operational consultants and process automation experts assess your existing and planned network infrastructure, control systems and SCADA systems with an emphasis on security and survivability. For example, we provide instrument / control device investigation, instrument calibration, control system validation and remediation, reengineering and recommissioning of plant and business systems, and supplemental in-house support as long as you need it.

FEED and Detailed Design

Front-end engineering design (FEED), also called detailed design, is the second phase of an engineering project. FEED follows the feasibility study and often happens prior to final process automation project approval. The phase is useful because it can be used to generate bid tabs, which can then be used to develop an investment quality cost estimate. Revision 0 P&IDs are usually generated during FEED for process automation projects that involve the instrumentation and control system — for example, for grassroots projects, major unit revamps and control system upgrades. MAVERICK engineers have taken responsibility for FEED generation on many process automation projects over a wide variety of industries, ensuring that they stay within the approved scope and budget.

I&E Design / Engineering

A plant’s instrument and electrical (I&E) system is critical to process automation. MAVERICK provides design, engineering and troubleshooting services for these systems to ensure the quality and proper integration of the system components, motor control circuits, power supplies and PLCs.

Process Analysis

A clear understanding of plant processes is critical to developing a sound process automation system design with improved plant operation and productivity. The key to this understanding is process analysis, which includes reviewing the P&IDs and plant operating data and then gathering input from operations personnel through key interviews. This analysis uncovers the key operating goals and targets and the important product quality variables, as well as the constraints, limitations and bottlenecks that challenge operators. The best process automation system designs create the tools that empower operators to overcome the challenges and meet key goals and targets. MAVERICK’s process control engineers apply sound process analysis on all process automation projects.

Programming and Configuration

Programming and configuration brings to life the detailed design of the instrumentation and control system that is developed during the font-end engineering design (FEED) phase of process automation. MAVERICK’s control engineers have extensive experience working with every major DCS and PLC system. They apply this process automation knowledge in using the latest engineering tools to convert logic diagrams into PLC ladder logic, to write generic and custom code and to build I/O and control applications using standard system function blocks and other features. With the features available in modern control systems, even complex advanced control strategies can be configured and programmed in these systems.

Project Management

Project management is one of the most important factors in the success of a process automation project. MAVERICK employs the Project Complete® approach to project management, in which our project managers execute at every stage in the process automation project lifecycle: definition, design, development, deployment, direction and documentation. This eliminates many of the problems that can keep a process automation project from meeting its scheduled requirements.


MAVERICK understands that in today’s business world of enterprise-wide facility integration, many companies are concerned about the risk of exposing process control systems to networks that have connectivity beyond the plant’s boundaries. MAVERICK works with each process automation client to ensure that every network is sufficiently armored to mitigate the risk of unwanted intrusion.

Systems Design

During process automation, MAVERICK provides top-to-bottom design of integrated control, MES and business systems. Our design expertise spans the spectrum, including electrical and instrumentation, DCS, PLC, HMI and SCADA implementations; I/O point configuration; advanced process control; and control and business networks.

Systems Development

MAVERICK’s Project Complete methodology is the basis for our systems development service offering. This applied methodology ensures that our team follows good engineering practices during all phases of development, including system configuration and setup; control, HMI and SCADA programming and configuration; historian configuration and database programming; business interface development; and documented testing. All phases of software development are subject to revision control and documentation.

System Implementation

Our breadth of process automation services allows us to provide comprehensive implementation of our engineered solutions, including technical services to support the electrical and instrumentation installation and calibration, engineering to support the control system commissioning and startup and post-startup support.

Consultative Services

With decades of experience in process automation, MAVERICK provides expert manufacturing consulting services to resolve your growing pains and headaches with immediate, effective process automation solutions. Our consulting team can help you identify and eliminate the specific operational constraints that impact your profitability, such as distribution inefficiencies; outdated, underutilized or inappropriate technologies; capacity bottlenecks; organizational resource leveling; manufacturing, scheduling and planning issues; and inadequate strategic vision. With MAVERICK’s help, you can turn your pain points into strengths for your business.

Product Manufacturers Optimize CIP Systems

Product Manufacturers Easily Optimize CIP Systems

MAVERICK upgrades CIP systems and provides CIP editing software which allows easy management and optimization of CIP operations.
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Food Manufacturer Plans Expansions

Leading Food Manufacturer Plans Plant Expansions

A leader in authentic and premium food and beverage brands, including extended shelf life (ESL), organic, natural and indulgent favorites, partnered with MAVERICK to baseline current plant operations and develop a plan for upcoming plant expansions.
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Capabilities for an Established Food System

New Capabilities for an Established Food & Beverage System

An international beverage manufacturer needed to add fruit juice processing capabilities to an existing carbonated beverage facility. They required a control system and manufacturing execution system to monitor and supervise this fully automated batch process.
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Producer of Soy Protein Streamlining Business Process

Major Producer of Soy Protein Seeks to Retain Competitive Edge by Streamlining Business Processes and Improving data Availability “from the Plant Floor to the Boardroom.”

A global leader in the manufacturing and marketing of high-quality soy ingredients realized that in order to respond to stiffening competition, its business processes needed the agility to provide the right information to the right people at the right time.
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Manufacturers Utilize Auditing Techniques

Manufacturers Utilize Auditing Techniques to Improve Beverage Packaging Efficiency

Many manufacturers aim to improve operational efficiencies of beverage packaging, generating bottom-line cost savings by reducing equipment outages and material waste and improving system throughput. MAVERICK has helped them achieve these goals through physical equipment assessments, machine downtime audits, production team interviews, root cause analysis, audit team observations and equipment line balancing.
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Chemical Manufacturer Extends Catalyst Life

Major Chemical Manufacturer Improves Ethylene Oxide (EO) Selectivity and Extends Catalyst Life by Implementation of DCS-Resident Advanced Process Controls (APC’s) and Operator Advisory Tools

You’ve got what it takes to meet your goals. Now take your plan to the plant floor with MAVERICK.
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Plastics Manufacturer Increases Production

Major Plastics Manufacturer Increases Production and Reduces Operator Workload Through Advanced Process Control (APC)

A European manufacturer of high-value engineering plastics needed to boost its production rate to meet increased demand for Bisphenol A (BPA), a key intermediate, and the final product, a high-value polycarbonate resin. Although there were no immediate plans to install new equipment, and all other debottlenecking steps had already been performed, the manufacturer had to find a way to maximize its production of BPA.
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Fertilizer Manufacturer Implements Integration Solution

Fertilizer Manufacturer Implements Plant-Wide Systems Integration Solution

A manufacturer of water-soluble fertilizer needed to integrate its plant floor controls with its manufacturing execution system (MES) and enterprise resource planning (ERP) system to improve production monitoring and optimize plant utilization.
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Chemical Manufacturer Reduces Waste Disposal Costs

Major Chemical Manufacturer Reduces Waste Disposal Costs Through Advanced Process Control (APC)

Due to site-wide production rate increases from several process units, the organic waste streams at a chemical plant had grown beyond the combustion capacity of its waste fuels boiler (WFB). Waste that wasn’t burned in the WFB had to be shipped off-site for disposal at a significant (per pound) cost to the business.
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Advanced Process Control Improves Sulfur Content

Hydrotreater Advanced Process Control Improves Control of Product Sulfur Content

Due to frequent changes in the compositions and charge rates of mixed middle-distillate streams, the final product sulfur content of a diesel hydrotreating unit was subject to major upsets, thereby jeopardizing the ability of the refinery to maintain final blended diesel within mandated sulfur specification limits. Control of this most important process variable was a constant challenge for the process operators and was a source of major frustration.
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Petroleum Refinery Converts to Digital System

Major Petroleum Refinery Converts to New Digital Automation System

The client wanted to complete a platform migration as Phase I of a plant-wide modernization project. The client requested a Wonderware human machine interface (HMI) for the newly developed graphics.
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Modernization of Generator Control Systems

Fast-Paced Modernization of Generator Control Systems Meets Increased Power Demand

When Santee Cooper, a leading southeastern utility provider, inherited peaking generator with unreliable control systems, the company launched a modernization project to systems’ reliability and ease of operation. Unfortunately, the company lacked adequate monitoring capabilities and documentation regarding system maintenance.
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Power Plant Owner in Need of Process Control

Industrial Power Plant Owner in Need of Process Control Programming — ASA

An owner of a new power plant uncovered problems with the control system programming. Three months from startup, the plant required immediate assistance to resolve programming and control issues in order to meet operational requirements.
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Automatic Generation Controls in Power Plant

Advanced Automatic Generation Controls (AGC) in Power Plant

An independent power producer needed advanced AGC in order to achieve competitive, market-based, remote dispatch control certification.
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Manufacturer Integrates Vision Inspection System

Manufacturer of Currency Paper Integrates Vision Inspection System to Ensure 100% Consistent Quality

A manufacturer of high-quality paper sought a vision inspection system that would ensure its U.S. currency paper consistently satisfied federal government standards. The speed, accuracy and 100% reliability of this system were essential.
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Manufacturer Improves Accuracy of Testing

Airline Manufacturer Improves Accuracy of Testing with New Touch Probe Certification System

The project goal was to design and build a three-axis test system for recertifying touch probes used in the production and assembly of airplane parts and assemblies. The touch probes are ultra-accurate, ruby-tipped sensors used to verify machining and assembly tolerances on all aircraft to .0001 inch. The yearly recertification of the probes is required to meet current Federal Aviation Administration (FAA) specifications, and the OEMs do not provide secondary testing or recertification services.
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Manufacturer Implements Facility Control System

Semiconductor Manufacturer Implements Facility Monitoring and Control System (FMCS)

The client required the design and installation of an FMCS to provide continuous monitoring and control of the cleanroom environment, utilities plant and support areas for its wafer fabrication facility.
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Manufacturing Facility Requires Fast-Track Construction

Pharmaceutical Manufacturing Facility Requires Fast-Track Construction and Production with 100% FDA Compliance

A manufacturer of high-quality pharmaceutical eyewash solutions needed to establish new systems to ensure consistent satisfaction of Food and Drug Administration (FDA) standards. The speed, accuracy and 100% reliability of these systems are essential.
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Power Plant Upgrades Control System

Power Plant Upgrades Control System

A Fortune 300 company selected MAVERICK to upgrade an existing Modicon 984 PLC control system used to manage the operation of the overall water demineralization process with a state of the art redundant Allen‐Bradley ControlLogix micro‐processor based control system.
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Compound Producer Leverages Wonderware MES

Leading Vinyl Compound Producer Leverages Wonderware MES

MAVERICK partnered with a major vinyl compound manufacturer to develop a manufacturing execution system (MES) based on Wonderware MES which retrieves process order data and returns finished goods, raw material consumption and downtime to the SAP enterprise system.
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Brewery Performs Water Usage Study

Large American Brewery Performs Water Usage Study

A large brewery partnered with MAVERICK to perform a water balance and usage study.
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Data Acquisition System Developed for Solar Cell Stringer

Data Acquisition System Developed for Solar Cell Stringer

MAVERICK was selected by a major supplier of photovoltaic (PV) manufacturing equipment to develop a data acquisition system for their flagship solar cell stringer.
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MAVERICK Develops MES Application with Recipe Management

MAVERICK was selected by a major supplier of PV manufacturing equipment to develop a MES application with integrated recipe management for their modular solar panel production line.
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System Developed for Water Filtration

Product Quality System Developed for Water Filtration Module Production Line

MAVERICK developed a product quality system (SCADA) for a new, flexible water filtration module production line of a major supplier of water filtration solutions.
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Manufacturer Implements MES Upgrades

Water Filter and Purification System Manufacturer Implements MES Upgrades and Enhancements

MAVERICK was tasked with performing a risk analysis and deployment strategy for a system upgrade to the customer’s existing installations of Rockwell’s FactoryTalk ProductionCentre.
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Facility Develops Product Quality System

Steel Plate Heat Treat Facility Develops Product Quality System

MAVERICK partnered with a major steel supplier to develop a system that proves the quality of each plate produced by documenting the product genealogy. In an industry awash with foreign imports, this supplier is able to differentiate its superior offerings from those of inferior producers through the use of this system.
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Heat Recovery Steam Generator (HRSG) Support for Smelter

MAVERICK was contracted to support the startup of HRSGs for the power block on the largest aluminum smelter complex in the Middle East in Abu Dhabi, United Arab Emirates.
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(HRSG) Support for Saudi Arabia

Heat Recovery Steam Generator (HRSG) and Balance of Plant Support for Saudi Arabia

MAVERICK was contracted to support the commissioning and start‐up of a new GE installation in Saudi Arabia for the first Integrated Independent Water and Power Project (IWPP) in Saudi Arabia, producing 2800 MW and 210 MGD of water in Jubail City, Saudi Arabia.
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Leader in Feedstock Builds Second Plant

Leader in Bioproduct Feedstock Builds Second Pilot Plant

A company that develops high quality feedstock for the bioproduct and biofuel supply chain awarded a second contract to MAVERICK to provide engineering and to commission the control, human‐machine interface (HMI) and data historian systems for its second pilot plant.
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Producer Restarts Mothballed Mill

Major Pulp and Paper Producer Restarts Mothballed Mill

A major pulp and paper company partnered with MAVERICK to restart an integrated pulp and paper mill that had been shut down for two years.
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Paper Mill Sets New Benchmark for Migration Project Start‐up

Paper Mill Sets New Benchmark for Migration Project Start‐up

As a key step of the full replacement program of the 1980s vintage DCS and PLC systems, new primary and secondary Rockwell ControlLogix processors for the paper machine were programmed and installed along with new Rockwell drive systems and Emerson DCS.
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