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Conveyor Control Systems Built to Run
PLC, HMI, and warehouse control system engineering for distribution, fulfillment, and manufacturing operations.
Conveyor Control Systems Built to Run
PLC, HMI, and warehouse control system engineering for distribution, fulfillment, and manufacturing operations across the Intermountain West.
One Team, Sensor to Shipping Data
Modernize Without Stopping the Line
Engineered, Installed, and Serviced by HOJ
Case Conveyor Systems We Build
WMS to WCS Integration
PLC Programming and Retrofit
HMI and SCADA
Sortation and Diverter Controls
Motor Controls and VFDs
Industrial Networking and IIoT
Your Conveyor Is Choking Throughput
You bought the equipment. The bottleneck is the controls. Three problems show up in almost every line we audit.
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Your WMS and PLC Don't Talk": Orders sit in queue. Operators key in data twice. Carrier lanes get the wrong totes. The line runs, but the data doesn't.
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Sortation Errors Eat Your Margin": Missed reads. Late diverts. Jams at the merge. Every mis-sort costs you a re-handle, a rework, or a chargeback.
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Legacy Controls Are a Liability": PLC-5 panels nobody can program. HMIs running on Windows XP. One bad card and the line is down for a week.
One Team for the Whole Stack
We engineer the controls, integrate the WMS, build the panels, and service the line. From sensor to shipping data.
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WMS, WCS, and PLC, Working Together": We design the messaging layer between your warehouse management software, control software, and the conveyor itself. Real-time, two-way, deterministic.
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Sortation That Hits the Right Lane": Encoder timing, sensor placement, redundant scanning, and fail-safe diverter logic. We tune the line until mis-sorts are the exception, not the norm.
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Modernize Without Ripping It Out": Phased PLC migration, HMI upgrades, network retrofits. Keep the iron. Replace the brain. Run through the whole upgrade.
Testimonials
Every HourbrokenDown Is Real Money
Fulfillment operations report unplanned conveyor outages costing roughly $20,000 per hour.
Micro-stops alone erode up to 25% of shift time.
Three things that compound when controls are broken: Manual data entry between WMS and the floor. Overtime to clear weekend backlogs.
Customer chargebacks for late and wrong shipments.
Run Like It Was Designed To
Orders flow from WMS to PLC without a human in the middle. Sorters hit the right lane the first time. Operators see what's happening, not just what broke.
Three Steps to a Stable Line
Book a Controls Assessment
A controls engineer walks your line, reads your WMS architecture, and identifies what's costing you throughput.
Get a Phased Plan
We give you a written roadmap with options, costs, and timeline. Retrofit, integration, or full system. Your call.
We Engineer and Install
One team, start to finish. Engineering, panel build, programming, integration, commissioning, and service.
Controls That Connect to Your Host System
Our controls integrate with whatever software processes your orders, whether that is SAP, a WMS, or a custom platform. That order data drives every divert and merge decision on the line.
Conveyor controls merge and divert cartons and totes to the right pick zones, then to the right outbound destination.
Release limits cap how much volume enters the system so traffic never backs up. AMR controls manage fleet traffic and task assignment for autonomous mobile robots.
Real-time visibility is available as an option. Count totes in the system, find the last scan on any order, and get an estimated arrival time at the dock.
Service That Shows Up Fast
When a line goes down, you don't need a phone tree. You need a truck and a tech.
We have 70+ service vehicles across the region. Emergency service: Trucks rolling within hours, not days.
Preventive maintenance: Scheduled PMs that catch jams, mistracking, and roller seizure before they stop the line. Parts: Critical spares stocked locally.
FAQs
What's the difference between WMS, WCS, and PLC?
The WMS tracks what to ship. The WCS decides which path each tote takes. The PLC tells the motors and diverters what to do. Most line problems live at the handoff between these three layers, not inside any one of them.
Should I retrofit my conveyor controls or replace them?
If the iron is sound and the logic is the problem, retrofit. If the panels, drives, and HMIs are all past support, replacement is usually cheaper over five years. We assess both and tell you the math.
How do I integrate conveyor controls with my WMS?
Three options: direct API connection, middleware as a translation layer, or full WCS in the middle. Each has tradeoffs in cost, flexibility, and future-proofing. We pick the one your data and ops actually need.
What is a conveyor control system?
A conveyor control system is the layer of hardware and software that runs your conveyor: PLCs, motor controls, sensors, HMIs, and the integration that connects them to your WMS. It decides what moves, when, where, and how fast. The conveyor is the body. The control system is the nervous system.
What are the different types of conveyor control systems?
Three layers usually run together. PLC controls handle motors, sensors, and diverters at the floor level. WCS (warehouse control system) software coordinates routing, sortation, and traffic between PLCs. WMS integration translates orders from the warehouse management system into commands the WCS and PLCs can execute. Most buyers need all three working together, not one in isolation.
How much does a conveyor control system cost?
Costs scale with scope. A targeted PLC retrofit on existing conveyor runs in the tens of thousands. A new WCS integration with HMI and panel work runs from low-six to mid-six figures.
A full controls system on a greenfield warehouse, including engineering, integration, and commissioning, runs into seven figures. The honest answer: cost depends on what you have, what you need, and how much downtime you can absorb during install. We give written estimates after we walk the line.
READY TO GET STARTED?
REACH OUT TO US TODAY
Whether it’s a project, product, repair or service, let’s chat to see if we can make your warehouse operations more efficient.
READY TO GET STARTED?
REACH OUT TO US TODAY
Whether it’s a project, product, repair or service, let’s chat to see if we can make your warehouse operations more efficient.