AES helped NPC modernize an aging scrap collection system by replacing outdated control stations with a centralized PLC-driven control panel, touchscreen operator interface, improved Lockout/Tagout support, and built-in capacity for future scrap line expansion.
Overview
NPC, a commercial print, mail, and digital communications company in Claysburg, Pennsylvania, was operating with a scrap collection system originally installed in the late 1990s. After years of modifications, the system had become difficult to control, unreliable to restart, and challenging to maintain safely.
AES engineered and delivered a modern scrap collection control system designed to improve reliability, simplify operation, support maintenance safety, and reduce the risk of production downtime.
What problem did AES solve?
NPC needed to replace a piecemeal control setup made up of multiple PLC relay stations and standalone control panels. The existing system had limited interlocking, no documented schematics, unreliable shutdown and restart performance, and poor support for Lockout/Tagout procedures.
AES provided a centralized control panel solution that gave NPC a safer, more reliable, and easier-to-operate scrap collection system with room for future expansion.
Scope of Work
- Centralized Control System
- PLC-Driven Control Panel
- Touchscreen Operator Interface
- Electrical Control Integration
- Lockout/Tagout Support
- Wiring Removal and Replacement
- Installation Coordination
- System Commissioning
- Operator Training
- Future Scrap Line Expansion Capacity
The Challenge
NPC’s aging scrap collection system had been modified many times since its original installation in the late 1990s. Over time, the system became increasingly difficult to operate, troubleshoot, and safely maintain.
The existing controls were spread across multiple independent panels with minimal interlocking and no documented schematics. Operators were hesitant to shut the system down because there was a real concern it might not restart, creating risk for production delays and maintenance complications.
The main challenges we had to address:
- The existing scrap collection controls were outdated and unreliable.
- Multiple independent control panels made operation and troubleshooting inefficient.
- Lockout/Tagout procedures were difficult to perform reliably.
- Operators had limited control over system performance and restart confidence.
- NPC needed capacity to add up to three more scrap lines in the future.
- The installation had to be completed within a tight shutdown window.
AES needed to deliver a modern control system that improved safety, reliability, and usability while minimizing disruption to NPC’s production schedule.
The AES Solution
AES engineered and delivered a centralized PLC-driven control panel to replace the multiple outdated control stations. The new system included a touchscreen operator interface, improved system visibility, better control access, and support for reliable Lockout/Tagout procedures.
To minimize downtime, AES worked closely with NPC’s engineering and maintenance teams to coordinate the installation. Before the shutdown, the new panel was set and wiring was roughed in. During the shutdown, outdated wiring was removed, new wiring was installed to code, the system was brought online, and AES completed commissioning and hands-on operator training.
AES System Components
The modernized scrap collection control system included:
- Centralized PLC-driven control panel
- Touchscreen operator interface
- Updated electrical controls
- System interlocking improvements
- Lockout/Tagout support
- New wiring installed to code
- Excess capacity for future scrap lines
- Commissioned control panel
- Operator training
- Custom integrated scrap collection control layout
The completed system gave NPC a more reliable way to control its scrap collection operation while improving safety, restart confidence, and long-term maintainability.
By replacing a piecemeal control setup with one centralized system, AES helped reduce operational headaches, simplify troubleshooting, support safer maintenance, and prepare NPC’s scrap collection system for future growth.
The Results
With the modernized scrap collection control system in place, NPC gained a safer, more reliable, and easier-to-operate system that helps support consistent uptime and improved maintenance procedures.
The new control panel was brought online in just five days, giving NPC long-term operational reliability, proper Lockout/Tagout support, and built-in capacity for future scrap collection expansion.
Download the Full Case Study
Download the complete NPC case study to see how AES modernized an aging scrap collection system with centralized controls, touchscreen operation, improved safety support, and future expansion capacity.
A Scrap Collection System Controls Upgrade Built for Reliability and Future Growth
This project shows how modern controls can extend the life and improve the performance of an existing scrap collection system. For NPC, AES replaced an unreliable, difficult-to-maintain control setup with a centralized solution built around safer operation, easier troubleshooting, and long-term scalability.
For commercial printers, mail production facilities, packaging plants, and manufacturers operating older scrap collection systems, AES designs custom control upgrades around the real production environment, maintenance needs, safety requirements, and future growth plans.
Frequently Asked Questions
A scrap collection system controls upgrade replaces outdated or unreliable electrical controls with a modern control panel, operator interface, PLC automation, and improved safety support.
NPC’s existing system had multiple independent control panels, limited interlocking, no documented schematics, unreliable shutdown and restart performance, and difficult Lockout/Tagout procedures.
The upgrade included a centralized PLC-driven control panel, touchscreen operator interface, updated wiring, improved control integration, Lockout/Tagout support, commissioning, and operator training.
The system was brought online in five days after careful pre-planning, panel placement, and wiring preparation before the shutdown window.
Yes. AES can modernize existing scrap collection systems with updated controls, operator interfaces, electrical integration, safety improvements, commissioning, and future expansion planning.
