"The expansion allows for the additional staff and workstations needed to produce higher volumes of controls that are more sophisticated," says Simonof.

The expansion coincided with the department's conversion from mechanical to programmable logic relays (PLRs) said to reduce the cost, size and potential failure associated with analog timers and hard relays, while adding digital programmability to individual equipment functions. The department also employs programmable logic controllers (PLCs) for more sophisticated equipment such as weigh batching systems, pneumatic systems and plant-wide bulk handling systems.

A new area equipped with simulated scale systems, electric motors, various sensors and other production-scale inputs and outputs allows 100 percent bench testing of monitoring and control functions.

According to Simonof, smart controls allow simple programming of equipment functions by the customer, and emailing of programs to and from the Controls Department for troubleshooting, reinstallation or customization.

In November 2007, the company doubled the size of its Engineering Department and increased engineering personnel by 50 percent.

Plant personnel can download programs to start, stop, slow, speed-up, delay, advance or cycle equipment functions.