INOIX Global Solutions
Transforming disconnected coating operations into a structured, centralized Cathodic Electrodeposition plant
Project Overview & Engineering Engagement
Executive Summary
NexTurner Technologies delivered a total automation overhaul for the INOIX Global Solutions CED plant. Moving from disconnected, manual operations to an integrated electrical cabling architecture and centralized PLC system, the plant achieved repeatable coating cycles, automated oven management, and comprehensive safety interlocking.
Scope of Work Delivered
- Complete plant field electrical infrastructure & power distribution
- Custom control panels with safety interlocks, circuit protection & PLCs
- CED coating sequence automation & closed-loop oven temperature control
- Full system validation, interlock testing & plant startup commissioning
Project Profile
- Client
- INOIX Global Solutions
- Industry
- Industrial Manufacturing & Surface Treatment
- Application
- CED (Cathodic Electrodeposition) Coating Process
- Engagement Model
- Complete Plant Electrical & PLC Automation
- Delivery Verification
- Full system validation & production plant startup
Engineering Problems That Demanded a Structured Solution
Operating without centralized control logic or coordinated electrical architecture created critical vulnerabilities across daily production.
Disconnected Operations
Plant machinery and treatment tanks operated independently with no synchronized control logic or communication backbone.
No Structured Cabling Architecture
Absence of formal power distribution or structured electrical cabling created safety hazards and complicated maintenance.
Unenforced Safety Interlocks
Critical safety dependencies between tank immersion mechanisms, chemical circulation, and baking ovens were unenforced.
Need for Digital Expansion
Management required a robust baseline automation layer capable of seamlessly scaling to HMI, SCADA, and cloud IIoT analytics.
Complete End-to-End Automation Flow
A structured multi-layer architecture connecting physical field devices through custom panel hardware to deterministic software logic.
Plant Field Work
Power distribution, structured cabling, and sensor/actuator field routing.
Control Panels
Assembled custom electrical panels, PLCs, motor control, and safety circuits.
CED & Oven Automation
Automated sequence timing, heat cycles, and coordinated tank transitions.
PLC Commissioning
Programming, interlock validation, startup diagnostics, and handover.
NexTurner's Technical Solution
From cable identification to sequence programming, our engineering team delivered a comprehensive turnkey scope.
Plant Field Work
Engineered plant-wide power distribution, structured containment trays, and industrial cabling across all CED process tanks and oven zones.
- Complete electrical infrastructure and heavy cable terminations
- Dedicated sensor and actuator signal routing with noise isolation
- Safe earthing and power distribution boards
Engineered Control Panels
Designed and fabricated custom PLC control cabinets with integrated thermal circuit breakers, motor starters, and safety interlocks.
- High-reliability industrial PLC platform integration
- Overload and emergency stop safety loop circuits
- Modular I/O termination blocks for future expansion
CED & Oven Automation
Engineered sequence control logic governing the precise timing of tank dips, transfers, drip times, and oven curing temperatures.
- Closed-loop PID temperature regulation for curing ovens
- Coordinated sequence logic for dipping, draining, and conveying
- Real-time fault handling and instant alarm annunciation
PLC Commissioning & Startup
Comprehensive on-site commissioning including point-to-point I/O validation, interlock trip simulations, and live operational trials.
- Signal calibration for temperature probes and level transmitters
- Full load testing under simulated and live production conditions
- Hands-on operator training and engineering handover
Project Outcomes & Operational Impact
The transformation delivered deterministic reliability, continuous equipment protection, and operator-independent consistency.
Centralized Equipment Control
All CED plant equipment is coordinated from unified control panels, completely eliminating isolated, ad-hoc manual operation.
Consistent Process Automation
Automated CED coating sequences and oven operation deliver repeatable, uniform film thickness and high surface quality.
Reduced Manual Dependency
Automated process cycles minimize operator intervention and eliminate human timing variability during dipping and curing.
Safety-Critical Interlocking
Deterministic interlock logic enforces strict dependencies—protecting shop floor personnel, heaters, and expensive chemical baths.
Real-Time Fault Detection
Rapid fault annunciation pinpoints the exact cause of any trip, allowing maintenance teams to resolve issues in minutes.
Scalable Digital Foundation
Structured automation infrastructure is 100% prepared for subsequent HMI, plant SCADA, and IIoT connectivity layers.
Digital Transformation & Industry 4.0 Roadmap
The electrical and PLC foundation establishes a clear, phased evolutionary pathway toward fully connected smart manufacturing.
Electrical + PLC Automation Foundation
Robust, structured automation foundation commissioned and validated across all CED systems.
HMI & Centralized Monitoring
Operator touchscreens providing live status, tank temperatures, and manual sequence triggers.
SCADA Implementation
Plant-wide alarms, historical trending, chemical bath analytics, and supervisory oversight.
IIoT Integration
Connected sensors, cloud data aggregation, and remote visibility dashboards for executives.
Smart Manufacturing
Real-time OEE, automated energy tracking per batch, and predictive maintenance algorithms.
Transform your operations like INOIX Global Solutions
Contact our industrial automation engineers to discuss requirements, architecture, and project estimates.