Advanced Engineering Solutions | Systems & Control, IIoTs, Digital Twins

Welcome to IACS Engineering — your 24/7 global partner for OT–IT integration, Industry 4.0 enablement, multi-vendor communication protocol profiling, advanced process control engineering, and reusable controller library development.

With more than 20 years of consultancy and engineering experience, our team of highly qualified professionals (PhD, MEng, BEng) — including Principal Control Systems Engineers, Senior Control Systems Engineers, and Senior Process Control Engineers — has delivered solutions across diverse sectors such as food & beverage, pharmaceuticals, manufacturing, material handling, robotic warehouses, energy storage systems (ESS), mining, and water & wastewater treatment.

At IACS Engineering, we bring together deep expertise in both Operational Technology (OT) and Information Technology (IT) to provide specialized engineering services that accelerate your Industry 4.0 transformation and drive reliable, scalable, and intelligent automation.

IACS Engineering – Design & Development Capability Matrix

Engineering Designs & Development Capabilities

System Architecture & OT/IT Network Topology Design
Control Loop Architecture: ON/ OFF, PID Control, Pressureless Conveyor Control (PCC), Leader–Follower Control
Advanced Process Control: Cascade PID Control, Split-Range PID Control, Ratio Control, and MPC (Model Predictive Control)
Functional Design Specifications (FDS): Control Philosophy, Alarm Philosophy, States, Fail-safe Logic, Interlocks, Permissives
Process Control Object Libraries & Digital Twin Simulation Objects
Inspection & Test Plans (ITP), FAT/SAT development with PFDs, P&IDs, Electrical Schematics, IO Lists
API Development for Automation & IIoT
R&D Case Studies in Process Modeling, Control & Communications
Energy Optimization & Control Cost Studies
Circular Economy Integration for Recycled Material Streams

Process Control Objects Library Development

Object-oriented IEC 61131-3 structured, reusable, & maintainable libraries
Multi-vendor Experience

Digital Twin / Simulation Library Development

Simulation frameworks for testing control libraries
Portable FAT/SAT testing simulators
IO simulation, sequences, interlocks & alarms
Auto-filled FAT/SAT reports with timestamps

Process Optimization

Optimal process parameter calculation
Multivariate regression analysis & data modeling

Communication Protocols

Ethernet/IP (CIP), PROFINET, Modbus TCP, OPC UA, MQTT, EGD, AS-i, SNMP, IEC 61850
DeviceNet, Profibus DP, CANbus, Modbus RTU, DNP3

Industrial IoT Experience

Azure IoT Hub & Azure IoT Edge
Custom APIs (Modbus TCP, OPC UA, MQTT)

International Standards Experience

ISA-88 Batch Process Control
ISA-106 Procedure Automation
ISA-95 Enterprise Integration
IEC 61131-3 Object-Oriented PLC Programming
ISA-18 Alarm Management
ISA-5 / ISA-20 Instrumentation Documentation
ISA-84 / IEC 61511 Functional Safety

Why Choose Us for Industrial Automation & Control Systems Engineering

Expertise That Delivers Results

With over 20 years of experience in industrial automation, process control, control systems engineering, and R&D in advanced control theory, we provide high-performance engineering solutions that improve reliability, efficiency, and operational excellence.

Complete Functional Design Specification (FDS) Development

Functional decomposition & hierarchical control layers
System states, modes, and operational transitions
Software architecture & structured programming
Control philosophy development
Permissives, interlocks & fail-safe logic
Alarm management philosophy
Communication protocol profiling
Automation layers integration (ERP, MES, SCADA)
Sequence modeling & state-based control design
Collaborative robotic process automation (RPA)

ISA-95 Implementation Expertise (Enterprise-Control System Integration)

Manufacturing Operations Management (MOM) & Layered ISA-95 architecture
Level 3–Level 2 integration frameworks for MES–SCADA
ISA-95 structured data models for assets, materials, and operations
Standardized tag naming, equipment models & terminology harmonization
Production workflow, scheduling & resource modeling
Information exchange models for KPIs, OEE, downtime & traceability
Designing interfaces between ERP (SAP, Oracle, Microsoft) and MES/SCADA
Implementing Level 3 functions: production, quality, maintenance & inventory operations
Secure, reliable industrial information flow across enterprise systems

Transparent & Predictable Pricing Schedule

Principal Consultancy: *from USD 149/hour (plus GST/VAT)
Senior Control Systems / Senior Process Control Engineers: *from USD 89/hour (plus GST/VAT), minimum 4 billable hours
Flexible Engagement Models: fixed-price, retainer-based, or project-based agreements

You always know exactly what you’re paying for—no surprises, no hidden costs.

Project-Based & On-Demand Freelancer Engagement

For well-defined automation and control engineering projects, we provide project-based and on-demand freelance support through vetted subcontractors and specialist engineers. This model ensures flexible and cost-effective execution, without the need for long-term commitments.

Vendor Agnostic, Independent Consulting

We deliver unbiased, vendor-agnostic consulting focused entirely on the solutions that best fit your operational, technical, and industry requirements. Our recommendations are not influenced by any specific OEM or technology provider.

Training, Upskilling & Knowledge Transfer Sessions

We provide custom one-to-one training, team upskilling, and knowledge transfer programs tailored to your automation systems, process control needs, and digital transformation roadmap. These sessions strengthen long-term capability within your engineering and operations teams.