Industrial facilities employ automation and control system solutions at scale, with spending forecast at $89.5 billion in 2025. Despite economic uncertainty, manufacturers and industrial facilities are replacing legacy systems and adding new automation solutions to future-proof their businesses and improve operations.

Smart facilities leverage automation in a variety of ways. Rockwell Automation’s State of Smart Manufacturing Report, a survey of 1,500 manufacturers and operators, reported that emerging technology, introduction of artificial intelligence, and taming cybersecurity risk are among the priorities.

Is your in-house team up to task, and can you afford to pull them away from their regular duties to have them focus their efforts as control system integrators? It’s a question many industrial facility managers ask. Both approaches have pros and cons, which we’ll explore. First, however, let’s start with some basics.

What is an Automation Control System and Its Benefits?

An automation control system is a technology-driven solution that manages, monitors, and controls industrial equipment. These systems consist of hardware (such as sensors, controllers, and actuators) and software (like SCADA control systems) that work together to improve operational efficiency.

Benefits of automation control systems include:

• Increased productivity, efficiency, and resource allocation
• Enhanced safety by reducing human intervention in hazardous environments
• Improved consistency in manufacturing processes
• Lower operational costs by reducing waste and optimizing energy consumption

What Are the Benefits of an Integrated Automation System?

An integrated automation system streamlines operations by connecting machines, software, and data into a cohesive framework. Key benefits include:

• Operational control in a centralized platform
• Better data visibility through real-time monitoring
• Increased flexibility to adapt to changing production needs
• Seamless communication between different control layers

What is Control Design in Industrial Automation?

Control design in industrial automation is the process of developing and implementing systems that regulate machine functions and performance. This involves selecting appropriate controllers, programming logic, and designing networks to ensure seamless integration across production lines.

Key components of control design include:

• Programmable logic controllers (PLCs)
• Supervisory control and data acquisition (SCADA) control systems
• Human-machine interfaces (HMIs)
• Industrial networks for real-time data communication

What is the Role of a PLC in Process Control Systems?

A programmable logic controller (PLC) is a digital computer used to automate processes in industrial environments. PLCs are the backbone of SCADA control systems, enabling facilities to monitor and control critical processes efficiently.

Advantages of PLCs in process control include:

• High reliability, even in harsh industrial environments
• Scalability for small to large automation applications
• Seamless integration with SCADA control systems and enterprise solutions

What Are the Types of System Integration?

Industrial facilities can choose from several types of system integration, depending on their needs:

• Horizontal integration: Connecting different automation systems across production lines.
• Vertical integration: Integrating automation systems with business applications (ERP, MES, SCADA).
• Enterprise application integration (EAI): Ensuring smooth data exchange between various industrial software solutions.
• Data integration: Merging real-time and historical data for better analytics and reporting.

In most cases, you would need a combination of these types or all of the above.

Control System Integrators vs. In-House Engineering

Next, let’s turn our attention to the subject at hand: should you use your in-house engineers or hire an expert control system integrator for your industrial facility?

While your in-house team will be more familiar with your current operations, they may have limited experience with other solutions. By comparison, a control system integrator is a specialized firm that designs, implements, and maintains industrial automation systems. These professionals work with manufacturers to ensure the smooth integration of control solutions.

Advantages of Using a Control System Integrator

Here are a few of the key advantages of using an expert control system integrator for your project.

Access to Specialized Expertise in Industrial Automation

Control system integrators bring years of industry experience to automation projects, ensuring they are executed efficiently. Their knowledge spans SCADA control systems, PLCs, and industry standards, making them valuable partners in complex projects.

Faster Implementation with Reduced Project Risks

External integrators have the resources and experience to deploy automation solutions quickly, minimizing downtime and reducing the likelihood of costly errors.

Ability to Work with Industry Leading Solutions

Many integrators have direct partnerships with industry-leading companies, for example, Rockwell automation integrators, giving businesses access to cutting-edge technology and best practices. Certified control system integrators for various vendors have deeper expertise into specific machine control solutions.

Cost-Effective

For businesses that do not require continuous automation updates, hiring a control system integrator can be more cost-effective than maintaining an in-house team.

Advantages of an In-House Engineering Team

When making your decision, you also need to consider the positives of sticking with your in-house team.

Full Control Over System Customization and Maintenance

An in-house engineering team allows the business to maintain full control over its automation systems, tailoring solutions to specific operational needs.

Direct Knowledge of Facility-Specific Requirements

Internal teams have an in-depth understanding of the facility’s unique automation needs, allowing for faster troubleshooting and system adjustments.

Managing Ongoing Automation Needs

For facilities with continuous automation requirements, investing in an in-house team may reduce long-term costs associated with hiring external integrators.

Challenges of Each Approach

There are also some challenges you should be aware of when it comes to the external integrator vs. in-house engineer debate.

Control System Integrators

While integrators bring expertise, they often require a higher initial investment. Additionally, companies may need ongoing contracts for system maintenance and support.

In-House Engineering

Building an internal team requires hiring skilled engineers and investing in training, software, and infrastructure, which can be costly and time-intensive. You also have to work hard to retain qualified engineers who are in high demand. Loss of institutional knowledge can be a significant concern.

Comparing the Pros and Cons: In-House Engineers vs. Control System Integrators

Let’s sum up the pros and cons, broken down by different factors you will want to consider.

There are some other key factors you will want to take into account when choosing between an in-house team and certified controls system integrators. For example:

• Project complexity and scope: Large-scale automation may require external expertise
• Budget constraints: Weighing upfront costs versus long-term savings
• In-house expertise: Ensuring internal teams have the necessary skills and experience
• Maintenance and support needs: Considering long-term automation upkeep

A Word About Cybersecurity

Another key factor in your decision should be cybersecurity.

As IT technology and operational technology (OT) continue to merge and use cloud resources, cybersecurity concerns are rising. Today’s networks of sensors and IoT devices can span hundreds or thousands of endpoints, each of which can be an attack surface.

A survey cited by the International Society of Automation shows how big a problem this has become. 80% of manufacturing firms globally report a “significant increase in overall security incidents or breaches” last year. Less than half (45%) said they were adequately prepared to deal with breaches

Where systems in the past typically air-gapped equipment and operational tech, this convergence of IT and OT makes that more difficult. You need a high level of experience to understand modern cybersecurity threats and weave security into every aspect of your automation.

It’s a security issue and a safety issue.

There’s a reason those responding to Rockwell’s survey cited cybersecurity as the third most important issue, behind only rising prices and energy costs. A Texas water facility was attacked by a group with possible ties to Russia, forcing a water tank to overflow. While it didn’t affect the quality of the drinking water, it demonstrated how attackers could gain control of operational systems and machine controls. In similar attacks, hackers accessed a system in San Francisco and deleted the program used to treat drinking water. A Florida location was hit, raising the levels of lye in drinking water to poisonous levels.

Industry Sector Experience

You want to think about industry experience as well. Industrial automation includes a wide range of uses across multiple sectors. Expertise in specific industries can make a difference in understanding operations and deploying best practices. This becomes especially apparent when you look at the different types of automation and machine control systems in different industries:

• Manufacturing assembly lines: Robotic arms and conveyor systems that automatically assemble products like automobiles, electronics, and consumer goods.
• Power generation plants: Automated control systems that regulate electricity production and distribution while monitoring for faults or inefficiencies.
• Oil and gas facilities: Remote monitoring systems and automated control valves that regulate flow, pressure, and temperature in refineries and drilling operations.
• Smart factories: Fully integrated production environments where machines communicate with each other and make autonomous decisions based on real-time data.
• Warehouse management systems: Automated storage and retrieval systems that use robots to locate, pick, and transport inventory in distribution centers.
• Food processing plants: Automated equipment that handles sorting, washing, cutting, cooking, packaging, and quality control for food products.
• Pharmaceutical production: Precision automation systems that ensure accurate measurement, mixing, and packaging of medications while maintaining strict quality standards.
• Agricultural automation: Autonomous tractors, drone monitoring, and automated irrigation systems that optimize crop yields and resource usage.
• Mining operations: Autonomous drilling, hauling, and excavation equipment that improves safety and efficiency in hazardous environments.
• Textile manufacturing: Automated looms and cutting machines that transform raw materials into finished fabrics and garments with minimal human intervention.

At first glance, this may tilt the scale in favor of in-house engineers who have experience in industry-specific applications. However, you will need to weigh that against control system integrators who have done hundreds (or even thousands) of installations and have expertise in best practices and cutting-edge solutions.

External and Internal Obstacles to Optimization

Regardless of the direction you choose, you want a customized solution that is optimized for peak efficiencies. However, organizations these days are dealing with significant obstacles to building operational efficiency with industrial automation.

Here are the top five concerns that industrial operators cited as their biggest obstacles:

An experienced industrial automation solutions provider is key to overcoming these challenges. Your best solution, however, will likely be collaboration. Control system integrators will work closely with your in-house engineering team to create an ideal—and optimal—solution.

How to Choose a Control System Integration Company

When looking for a control system integrator near you, here are some of the things you will want to look for.

Technical Expertise and Industry Experience

Choosing a company with a strong track record in industrial automation and machine controls ensures that your systems are designed and implemented effectively. Look for certifications, case studies, and client testimonials to gauge their expertise.

An experienced provider will have deep knowledge of industry-specific challenges and a track record of innovation.

Customization and Scalability of Solutions

A good integration partner should offer solutions tailored to your specific facility needs while ensuring they can scale as your company grows. Look for providers that can integrate automation systems with existing infrastructure and adjust them to accommodate future expansions or process changes.

Assessing Cybersecurity Measures

Integrators must be highly experienced in cybersecurity and machine controls. Without robust cybersecurity, your entire operation is at risk. In industrial applications, this goes far beyond just data breaches. A breach of your OT can disrupt production and performance.

Vendor Partnerships and Technology Stack

The best integrators will have strong partnerships with leading automation firms, ensuring access to the latest hardware, software, and innovations. It’s a good idea to ask about their affiliations with key industry players and experience in integrating these systems. For example, if you are working with a particular SCADA control system or want a Rockwell automation integrator, ask whether they are certified control system integrators on these types of projects.

Cost vs. Value Consideration

Cost is always a variable, but it’s more about long-term value. If you save a few dollars upfront, but the industrial controls system doesn’t meet your goals for the long term, you’ll likely spend a lot more to upgrade or fix problems down the road.

One serious incident can negate any savings you might see, so always look at the total cost of ownership and place significant value on reliability, scalability, efficiency, and other operational issues when evaluating potential automation integration partners.

When considering industrial automation, machine controls, and control system integration, you can trust Pacific Blue Engineering. After more than 1,000 designs and installations, Pacific Blue Engineering has the expertise you need to create long-term solutions for your facility. Contact us today for a free consultation.