Siemens Control Systems for scalable factory control
Scalable factory control is rarely achieved by adding more equipment alone. The difference between a line that grows smoothly and a line that becomes fragile is the control architecture behind it. Siemens Control Systems are widely used in modern manufacturing because they support structured expansion, robust diagnostics, and consistent standards across sites, lines and cell types. When you design for scalability at the outset, you reduce future downtime, simplify upgrades, and make it easier to integrate new robots, machines and data systems as production evolves.
Premier Automation, founded in 2000, is one of the UK’s leading suppliers of robot-based automation and control systems. We design and manufacture new control systems for robots, special purpose machinery and process lines, and we also re-engineer, upgrade and relocate existing automation locally, nationally and internationally. As a Siemens Solution Partner, we are certified, trained and supported to deliver systems aligned with Siemens’ globally standardised criteria. In this guide, we explain what scalable control really means, what to expect from a professional control system project, and how the right Siemens platform helps you future-proof your factory.
Siemens Control Systems and what “scalable” really means
Scalability is often misunderstood. It is not simply the ability to add another conveyor, another robot or another cell. True scalability means your control system can expand without becoming harder to maintain, harder to operate, or riskier to change.
In practical terms, scalable control includes:
A modular architecture that allows new machines or cells to be added in a structured way
Consistent safety and compliance methodology that does not need reinventing each time
Clear HMI design that operators recognise across multiple lines
Standardised diagnostics and alarms, enabling faster fault-finding and reduced downtime
Straightforward integration with robots, peripherals, and higher-level systems such as MES/EMS and SCADA
Siemens Control Systems support this approach well, but scalability only works when design, documentation and commissioning are done properly. That is where an experienced partner adds value: not only specifying the platform, but engineering the whole system to deliver long-term uptime and maintainability.
Siemens Control Systems for robots, special purpose machinery and process lines
Premier Automation develops diverse automation solutions, from single-cell robot systems to sophisticated, multi-technology production environments. That means control systems must handle more than basic sequencing. A modern factory system often includes robot controllers, vision, safety systems, conveyors, tooling, machine tool interfaces, data capture, and communication with external equipment.
Siemens Control Systems are commonly specified in these environments because they can provide:
Reliable PLC control and high availability for critical processes
Structured programming practices that support ongoing modification
Compatibility with a broad range of industrial communications and field devices
An ecosystem that supports simulation, testing, and structured commissioning
For example, on robot-based automation, the PLC often controls peripheral equipment and communicates with the robot controller, safety devices, and upstream or downstream handling systems. For machine tending cells, it may also interface with CNC machine signals, part-present sensors, gripper status, and infeed or outfeed conveyors. For palletising, the PLC may coordinate infeed tracking, pallet management, stretch wrapper integration, and end-of-line safety.
The benefit of the right control approach is that you can update the process, change products, or increase throughput without rebuilding your control strategy from scratch.
Siemens Control Systems design: engineering, standards and documentation
A scalable control system is engineered on paper before it is built in steel. Premier Automation specifies and designs control systems for most automation requirements, executing the design in the latest Eplan platform. This is not just a drafting choice; it enables clarity, repeatability and better project control.
A professional design package typically includes:
Full schematics and parts lists
Panel layouts and cable schedules for efficient build and installation
Controls risk assessments and structured documentation for safer delivery
Safety reporting aligned with relevant standards, including EN ISO 13849 methodology where required
These deliverables matter because they reduce ambiguity. They also make future upgrades easier, because the next engineer can understand what was built and why. In scalable factories, documentation is not an afterthought; it is what keeps change safe and controlled.
Siemens Control Systems build and test: how quality is protected
Even the best design can be undermined by poor build quality. Premier Automation builds panels internally using fully qualified electricians, with pride in both workmanship and the overall appearance of every panel. That standard is important for long-term reliability, especially in industrial environments where vibration, dust, heat and continuous running are normal conditions.
Before despatch, panels are fully tested in the workshop and built to comply with relevant British and European standards and directives. That pre-testing reduces risk at site, shortens commissioning time, and improves the likelihood of a smooth start-up.
From a scalability standpoint, repeatable build and test processes also make it easier to replicate control panels across multiple lines or sites, supporting consistent spares strategy, consistent troubleshooting, and faster training.
Installation, commissioning and training: turning design into uptime
Installation and commissioning is where a control project either succeeds cleanly or becomes disruptive. A structured approach reduces downtime and helps teams adopt the new system quickly.
Premier Automation’s electricians connect the system to the control panel, power up and test supplies, then validate I/O. Software engineers then install and commission the control software and provide training as required. This staged approach is practical for both new installations and upgrades, where production constraints can be tight.
We also support off-line programming and simulation to minimise downtime. Tools such as RobotStudio and Siemens PLC simulation are used to create and edit programmes off-line, allowing modifications to be developed and validated before they are deployed on site. For high-throughput environments, this can significantly reduce disruption and accelerate ramp-up.
Upgrades and relocation: keeping existing assets productive
Scalable control is not only about new builds. Many factories have productive assets that need to be re-engineered, upgraded or relocated to meet new product requirements, improve cycle times, or increase throughput. Premier Automation provides system assessment visits to evaluate existing automation and build an upgrade plan aligned with technical and commercial criteria.
Common upgrade drivers include:
Obsolete components or ageing PLC and HMI hardware
Process changes requiring new sequences, tooling or interfaces
Increased throughput requirements driving cycle time optimisation
Relocation due to site changes or factory reorganisation
With the right Siemens-based architecture and documentation, upgrades become more predictable and less risky, enabling you to extend the life of existing assets while improving performance.
FAQs
What makes a control system “scalable”?
A modular structure, standardised documentation, consistent safety design, repeatable HMI/diagnostics, and an architecture that supports future expansion without major rework.
Can Siemens-based control integrate with robots and higher-level systems?
Yes. Most modern automation systems require PLC communication with robots, peripherals, and external systems such as SCADA or MES/EMS, which can be engineered as part of a complete solution.
Do you support changes after installation?
Yes. Premier Automation provides after-sales support, upgrades, re-engineering and relocation services to keep systems productive over time.
Next steps
If you want factory control that can grow with your production, Siemens Control Systems are a strong foundation, but only when engineered and delivered with the right design discipline and project experience. Premier Automation designs, builds, installs and commissions control systems for robots, special purpose machinery and process lines, and supports upgrades and relocations across the UK and internationally.
To discuss a scalable control project, speak with Premier Automation and arrange a technical conversation about your process, your payback criteria, and the most appropriate control strategy for your site.
