Recycling & Material Processing Automation
Rugged control, monitoring, and integration for sorting, conveying, baling, and material-processing systems.
Britton Electronics & Automation, Inc. designs, builds, programs, and supports automation systems for recycling, sorting, material handling, and processing facilities throughout Illinois and the Midwest.
These facilities operate in demanding environments where dust, debris, vibration, shock loading, and constant equipment wear are part of daily operation. BEA develops practical control systems designed around the actual process and operating conditions.
Sorting & Material Separation Systems
Sorting systems require coordinated control of conveyors, feeders, screens, magnets, optical sorters, air separators, and discharge equipment. BEA develops PLC, HMI, and SCADA systems that give operators clear visibility into the full material-processing line.
Equipment permissives, startup sequencing, material routing, speed monitoring, fault handling, and shutdown logic help protect equipment and reduce process interruptions.
Equipment sequencing, line-speed control, permissives, interlocks, fault handling, and coordinated shutdown.
Screens, magnets, optical sorters, air systems, feeders, diverters, and separation-equipment integration.
HMI screens, line status, alarms, equipment diagnostics, production totals, trends, and operator controls.
Highlights: Sorting lines • Screens • Magnets • Optical sorting • Material routing • Process diagnostics
Conveyors, Feeders, Balers & Compactors
Material-processing lines depend on conveyors, feeders, compactors, balers, and discharge equipment operating in the correct order. BEA develops control systems that coordinate this equipment and provide clear fault information when a line stops.
Motor starters, VFDs, hydraulic systems, plug switches, zero-speed sensors, pressure monitoring, and safety interlocks can be integrated into one coordinated system.
Startup sequencing, shutdown timing, speed monitoring, plug detection, overload protection, and diagnostics.
Hydraulic sequencing, pressure monitoring, ram position, interlocks, alarms, and cycle-status indication.
Motor starters, VFDs, current monitoring, speed control, fault diagnostics, and coordinated operation.
Highlights: Conveyors • Feeders • Balers • Compactors • Hydraulic controls • VFD integration
Rugged Controls & Equipment Protection
Recycling facilities expose control equipment to dust, debris, vibration, temperature changes, and frequent mechanical impact. BEA selects enclosures, components, wiring methods, and panel layouts appropriate for the environment.
Equipment protection and clear fault diagnostics are incorporated into the control system so operators and maintenance personnel can identify problems quickly.
Enclosure selection, environmental protection, cooling, documentation, field wiring, and maintainable layouts.
Plug switches, zero-speed detection, overloads, bearing temperature, pressure monitoring, and shutdown interlocks.
Equipment faults, process alarms, event history, remote notification, and troubleshooting information.
Highlights: Dust protection • Heavy-duty enclosures • Zero-speed detection • Bearing temperature • Motor protection • Alarm history
Vibration Monitoring & Predictive Maintenance
Bearings, gearboxes, motors, reducers, shredders, and rotating equipment can often show signs of developing problems before a failure occurs. BEA integrates vibration, temperature, current, and runtime monitoring into plant-control and maintenance systems.
Trends, warning limits, alarms, and equipment history help maintenance teams identify changes and prioritize inspections before a production-critical breakdown.
Vibration, bearing temperature, motor current, runtime, speed, and equipment-condition monitoring.
Historical trends, warning limits, alarm thresholds, notification, and maintenance-status visibility.
Equipment history, changing-condition indicators, inspection priorities, and planned-maintenance support.
Highlights: Vibration sensors • Bearing temperature • Motor current • Historical trends • Warning limits • Maintenance planning
Integration, Modernization & Field Support
Recycling facilities often operate with equipment from several manufacturers and multiple generations of control systems. BEA can integrate existing machines, packaged systems, legacy PLCs, and newer automation into one coordinated platform.
Connect existing PLCs, packaged machines, sorters, drives, instruments, and plant networks.
Replace obsolete PLCs, HMIs, drives, controls, and communication equipment in manageable phases.
Equipment testing, sequence verification, field startup, documentation, and operator training.
Rapid diagnostics, program support, drive troubleshooting, remote access, and production-critical service.
Highlights: Legacy integration • PLC upgrades • HMI modernization • VFD support • Field commissioning • Emergency service
Ready to improve your recycling or material-processing system?
From conveyor controls and sorting-line integration to vibration monitoring and emergency troubleshooting, BEA can help keep your facility operating reliably.