PRESS RELEASES

08/15/2014 - GCI successfully integrated an Allen-Bradley ControlLogix based control system at the Mack Trucks Macungie Assembly Operations facility in Macungie, PA in partnership with local Mack personnel and a global Volvo IT team. Our ControlLogix PLC/PAC (programmable logic controller/programmable automation controller) is integrated both with all existing production lines and also with a Volvo IT MES (Manufacturing Execution System) scheduler application and database. Production scheduling information is communicated to the PLC which is responsible for controlling assembly lines plantwide. The PLC also provides the MES application with detailed assembly line alarm information, which is then immediately distributed to concerned parties via e-mail and text messages. This enhances facility responsiveness to downtime events. New annunciation, data logging, and reporting tools also provide increased visibility of production line events and aid in the analysis of operational performance..

04/21/2011 - GCI to present at this year�s COAL PREP INTERNATIONAL. GCI will speak during the Plant Productivity & Maintenance conference Wednesday May 04, 2011. Two Technical Session will be presented, "Industrial Wireless Systems � Application Considerations" and "Automation of a Recommissioned Coal Processing Facility".

Industrial Wireless Systems � Application Considerations
GCI has deployed several remote monitoring and control systems for the coal processing, gravel processing, water utility, and waste water processing industries using wireless and other technologies. Attaining a level of experience and proficiency hasn�t, admittedly, come without a learning curve and some pain. In particular, implementing a robust remote monitoring/control system using wireless or other long haul technology requires more that setting up two radios and crossing your fingers. The upside presented here is what has been learned of tools and techniques that allow for better planning and successful start-up.

Automation of a Recommissioned Coal Processing Facility
GCI (Systems Integration Company) was invited to participate in the rebirth of the New Saint Nick decommissioned coal processing facility owned by Reading Anthracite near Pottsville, Pennsylvania. In this presentation, a discussion that focuses on the collaborated effort to design a cost effective control solution and the challenges associated with delivering a simplified operation will be addressed. Although no prior hands on experience with coal slurry separation, Reading Anthracite provided ample process flow and P&ID diagrams. With a strong background in process control and material handling systems, GCI introduced Reading Anthracite to ISA S88.1 terminology, modeled the entire operation, and developed a detailed set of functional and design descriptions. Together with invaluable assistance from the electrical contractor, the coal processing facility was resurrected to efficient operating capacity.

04/12/2011 - GCI provides a Pennsylvania utility with monitoring equipment for a new boiler installation. GCI was responsible for the design, fabrication and creation of as built CAD documentation. An L-shaped transmitter rack was supplied with 24 Rosemount 3051 transmitters. Each transmitter was plumbed with �� stainless steel tubing and equipped with a blow down valve. The electrical conduits carrying the transmitter analog signals where designed, installed and sealed to meet the requirements of an explosive environment. A marshalling enclosure was required for field device termination near the boiler. Two redundant transmitters needed to be mounted outdoors. GCI supplied a heated, fully insulated stainless steel NEMA4x enclosure to house the transmitters.

Accompanying photos:

02/28/2011 - GCI provided a leading tractor trailer truck manufacturer with 3 large LED message displays for their cab paint room. These message displays inform the operators at 6 paint stations what paint number and process step are currently active. GCI provided programming and start-up services for their Allen-Bradley PLC5 processor and for their A-B InView LED message displays.

02/25/2011 - GCI provided a leading clinical pharmaceutical packager with a Cognex In-Sight vision system for the inspection of DataMatrix barcodes printed on glass syringe barrels. Where conventional barcode readers would typically experience difficulties when presented with the optical distortions of a barcode wrapped around a small diameter tube, the Cognex IDMax� algorithm was employed to successfully decode these challenging 2D barcodes. The vision system was programmed to interface with the facility�s Manufacturing Execution System (MES) so the barcode data could be verified for every inspection. Through the Cognex In-Sight Explorer PC-based software application, operators and support staff can view the vision system�s acquired image that is overlayed with the inspection results

02/5/2011 - GCI provided emergency programming services for a leading manufacturer of injection molded take-out packaging . The customer took receipt of conveying/handling equipment that did not perform as needed. Their start-up commitment was days away, so they lacked the time to get the OEM involved to reprogram the equipment. GCI worked onsite with the customer, using their verbal description of the desired sequence of operation to reprogram the Allen-Bradley MicroLogix PLC from scratch. The reprogrammed equipment was then tested with the customer�s existing injection molder and robotic palletizer to confirm that proper operation was achieved. The customer was able to meet their start-up objectives and was provided with documented PLC code for future troubleshooting.

10/2/2010 - GCI assisted a leading pharmaceutical packaging company to meet their critical manufacturing deadline by providing custom machine design and fabrication services. A near duplicate of an existing machine needed to be built within a very tight timeframe, but the existing design documentation was incomplete and inaccurate. GCI dimensionally verified the customer�s machine parts and generated AutoCAD drawings to update the customer�s records. Where off-the-shelf components were not available, GCI worked with multiple machine shops to have the parts manufactured with a very quick turn-around time. The machine assembly process, control panel fabrication, and wiring were performed at our Bethlehem, PA facility.

10/28/2009 - GCI provided programming, integration and start-up services for the control of several custom marker packaging machines used by a leading crayon and marker manufacturer. The machine design featured a high speed marker transport, accumulation and servo-controlled delivery mechanisms, and a servo-based X-Y table for the indexing of marker totes to execute an efficient fill pattern. Control logic was executed in an Allen-Bradley CompactLogix processor and operator interaction was through an A-B PanelView Plus HMI.

05/05/2009 - GCI helped a leading confectionary manufacturer automate the process of decorating randomly oriented marshmallow treats. A Cognex In-Sight vision system was programmed to locate each marshmallow treat passing by on a conveyor. This location and orientation information is then provided to an Allen-Bradley ControlLogix PLC and Rockwell Automation motion control system that controls the alignment and tracking of multiple print heads to the marshmallow targets. This process improvement freed up a team of employees from the tedious and non-ergonomic task of hand-stamping each marshmallow treat on a moving conveyor.

Accompanying photo:

04/18/2009 - GCI provided a storage vessel liquid level monitoring and voice annunciation system to a leading cosmetics manufacturer. An Allen-Bradley SLC5/05 PLC monitors Endress+Hauser level transmitters installed in eight storage kettles. Tank levels are reported to multiple HMIs in the facility. Plant operators specify their connection pathways between these storage vessels, pumps, and production lines via simple touchscreen operations, mirroring their physical piping connections at a transfer panel. The PLC can then inhibit product pumps to prevent run-dry operation. Operators receive tailored voice messages from the annunciation system when the storage vessel that they are connected to is nearing an empty condition so they can take needed actions.

12/10/2008 - GCI provided a vision-based inspection solution to a leading PET plastic bottle blow molder. Various dimensional attributes of the PET bottle were inspected using a Cognex In-Sight vision system. Defective bottles were identified, tracked, and rejected in-line without stopping the blow molding process. Using the Cognex In-Sight Explorer PC software, the customer was able to select the bottle type to inspect and were also able to specify the allowable dimensional tolerances.

Accompanying photo:

10/1/2008 - GCI worked with a leading coating and converting manufacturer to replace their vision system lighting on an existing web inspection application. GCI provided a more cost-effective and reliable LED-based lighting solution from Smart Vision Lights to complement their Keyence vision system application.

7/21/2008 - GCI provided multiple vision systems to a pharmaceutical customer for the purpose of analyzing printed labels applied to pill bottle caps. Keyence CV-3002 color vision systems were used to inspect the label graphic immediately after they were printed and applied to the bottle cap tops. The Keyence vision application first determined which pre-trained pattern most closely matched the captured image of the label. If the pattern match was within allowable tolerances, then a more detailed analysis was performed. The colors of the image graphics were next examined to make sure the color attributes were within allowable tolerances, verifying correct operation of the color printer. This inspection information was forwarded from the Keyence vision systems to an Allen-Bradley ControlLogix processor that verified if the pattern match was correct. The Keyence vision systems also provided serialized inspection results and images over Ethernet to a PC database for archival data storage requirements.

4/15/2008 - GCI provides ongoing programming and application support to several thermoform and cold form machines used by a leading clinical pharmaceutical manufacturer in the packaging of pills in blister foil cards. Each packaging machine is equipped with a Cognex In-Sight vision systems used to verify the presence or absence of pills in the formed cavities of the packaging material. Through the In-Sight Explorer application, the user can perform a host of equipment setup, production and maintenance functions. The application is sufficiently flexible that the vision system can support multiple light sources, various pill shapes and sizes, and various cavity layout arrangements. Defects - such as missing pills - are detected, tracked, and marked without stopping the machine. The Cognex In-Sight application takes advantage of the Cognex patented geometric pattern matching technology, PatMax, so the customer can train the exact shape of the pill prior to each production run.

Accompanying photo:

7/1/2007 - GCI partnered with a leading packaging manufacturer to test the closure performance of a new design of child-resistant pill bottles and caps. GCI built a test fixture to emulate the fastening operation of the pharmaceutical customer�s capper machine. A GSE CP Techmotive torque controller and nutrunner system was programmed to drive the rotational fastening axis for evaluating specific torque profiles. Detailed studies using various cap application approaches, speeds, torque profiles, and temperatures were conducted to evaluate the fastening characteristics. Each test set concluded with post-capping inspections for fastening anomalies and package damage. GCI generated reports on the test results to aid in design analysis and improvements by the manufacturer.

4/13/2006 - GCI performed a complete electrical rebuild on an RA Jones Cartoner machine responsible for packaging crayons into 24-pack boxes. GCI was responsible for the electrical design, control panel fabrication, on-site wiring, installation, programming, and start-up services. Control logic was handled by an Allen-Bradley SLC5/04 processor and operator interface through an A-B PanelView 600 HMI. Keyence sensors were used to verify that crayons of the proper colors were loaded into each box.

3/27/2006 - GCI enables wallpaper manufacturer to increase production efficiency by developing and deploying APAL, GCI's Automatic Print & Apply Label system. APAL provides a bi-directional interface to the customer's business system incorporating workorder selection, order detail, quantity, scrap, downtime and labor tracking.

1/15/2006 - GCI designed, built, installed and commissioned control systems for two Thermal Oxidizers for a roofing material manufacturer. In addition to improved gas burner management, the new control systems provided improved data collection for EPA mandated compliance and data analysis. Temperature data was stored both locally using an electronic data logger (paperless chart recorder) and also remotely on an Archestra Wonderware InSQL Server database.

11/12/2003> GCI provided a leading cosmetics manufacturer with an inspection station that verifies the presence of a tubular stem within a fragrance pump spray bottle. The major challenge with this application is that the customer�s bottles vary significantly in both color and degree of translucence. GCI was able to solve this application using an Allen-Bradley MicroLogix PLC and Keyence fiber optic sensors that support multiple preset configurations, where each preset corresponds to a particular bottle type.