CASE STUDY: Small to Midsize Manufacturer Enhances Production Quality and Reduces Costs with Becker IoT Live Solution

Background: A Midwest-based manufacturer, with operations in three U.S. locations and the UK, struggled to justify the high costs of traditional PLC-based automation solutions. The company was using outdated equipment to monitor their nickel-plating baths, a process that was inefficient, costly, and posed safety risks to personnel. Given their diverse product line serving industries such as aerospace, military, industrial, medical, and dental, the manufacturer needed flexible, scalable automation. However, traditional automation options proved both expensive and complex due to the resources and time required.

Analysis: Becker’s team began by conducting a site inspection at the client’s Central Ohio manufacturing facility. Becker's applications engineers, in collaboration with the client's manufacturing leadership, carefully reviewed the manufacturing process to identify areas for automation. The Becker team provided training on equipment that could efficiently gather the data needed to improve the automation process. This collaboration fostered trust and led to the co-development of a customized automation solution tailored to the client’s needs. This hands-on, interactive approach helped secure stronger buy-in from the client’s team, increasing the likelihood of adoption and project success.

Solution: Based on the jointly developed scope of work, Becker Engineered Systems proposed the following equipment and services for the initial phase of the project:
· 3 Walchem Intuition 6 Nickel Controllers with prewired relays, combo Nickel + pH input board, flow-through nickel and pH sensors, Ethernet, and Modbus capability.
· Cooling coil.
· Degasser.
· 3 EHE46E1-PE Walchem solenoid-driven metering pumps with GFRPP/EDM/Ceramic/PTFE liquid ends, 115 VAC, 1.8A, 12 GPH, 60 PSI max, 4-20mA input, tubing, foot valves, and injection check valves.
· 6 EZB16D1-PE Walchem solenoid-driven metering pumps with GFRPP/EDM Ceramic liquid ends, 120 VAC, 0.8A, 1 GPH, 105 PSI max, 360:1 turndown digital speed, foot valves, tubing, and injection check valves.
· 3 EZB16D1-TC Walchem solenoid-driven metering pumps with PVDF/FKM/Ceramic liquid ends, 120 VAC, 0.8A, 1 GPH, 105 PSI max, 360:1 turndown digital speed, foot valves, tubing, and injection check valves.
· Becker Connected Systems IoT Live gateway, dashboard, and portal.
· Equipment calibration and commissioning.
· Client training on equipment operations, troubleshooting, and automation dashboard navigation.

Results: Fifteen calendar days after receiving the purchase order, Becker had delivered all equipment. Within 43 calendar days of the purchase order, the equipment was installed, commissioned, and the dashboard was operational on one of the three nickel-plating baths. After only a few days of
trialing the equipment and automation, the customer saw an improvement in nickel chemistry accuracy, increasing from 1% to 0.4%. This improvement led to better product quality, reduced chemical costs, and, most importantly, minimized employee exposure to safety risks. The more efficient process also decreased chemical usage and improved overall results.

Customer Feedback: The customer plans to complete the automation of the remaining two baths and intends to extend the equipment and automation solutions to additional plating processes.

Becker Engineered Systems Benefits:
· Collaboration: Becker worked closely with the client to develop a cost-effective solution, leveraging both Becker’s expertise and the client’s insights.
· Applications Expertise: Becker’s team listened to the client's challenges, asked the right questions, and proposed the optimal solution.
· Onsite Training and Commissioning: Hands-on training and commissioning ensured smooth adoption and project success for all stakeholders.
· Fast Turnaround: Becker delivered the entire equipment package within 15 calendar days of the purchase order, made possible by a large in-stock inventory, meeting the client’s urgent needs.