Barry-Wehmiller Network
Control System Integration

Control System Integration

Design Group is one of the largest System Integrators in the United States providing automation and control system integration services to the consumer products, life sciences and industrial sectors. The efforts of over 400 CSI professionals, within a nearly 1,500 person firm, provide Electrical Design Services, Packaging and Process Automation Solutions, Information Solutions, Project Management, and Validation and Regulatory Solutions to our clients. Design Group automation engineers are experts in PLC/HMI, PLC based SCADA, DCS and S88 batch control systems and MES solutions for a broad range of applications including legacy system and cross platform migration.  That expertise, combined with our standardized practices for design and execution, allows Design Group to deliver quality solutions with consistency and accuracy.

As a single source of accountability, we work to define the project requirements, develop hardware and software design specifications, and self-perform all programming and start-up. Instrument specification, hardware and electrical system design, panel fabrication, and software development all occur in closely coordinated project execution. This approach facilitates seamless integration and change management, shorter lead-times, and stable system performance for our clients.

ControlTech Automation is a world-class electrical equipment manufacturer specializing in the design, manufacture, and certification of industrial control and power distribution panels.

Design Group provides solutions for the following industries:

Food and Beverage | Design GroupLife SciencesIndustrialSemiconductorHousehold Personal CareOil and GasIndustrial Machinery and Equipment
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  • Electrical Design

    The Design Group team includes hundreds of degreed engineering professionals to ensure that all electrical designs and panels are designed to meet the specific needs of each client. We design our automation systems with specific operational goals in mind and intense focus on safety, accuracy, value, and reliability.

    Our design team provides factory acceptance test services based on customized FAT documents developed specifically for each application.

    Design capabilities include:

    • Schematic Development
    • Back Panel Layouts and BOM Development
    • Detailed Power and Environmental Design
    • UL/CSA and NEC Adherence
    • ARC Flash Analysis/Mitigation
    • AutoCAD, AutoCAD Electrical, and MicroStation Services
  • Control Panel Solutions

    Design Group provides industrial control panel solutions for packaging, process, facilities, utilities, and other industrial applications through our ControlTech Automation division. We strive to earn repeat business by offering quality, value, and service above and beyond our competitors.

    Our designers are degreed engineers, professionals, and highly skilled electrical technicians that bring extensive experience to the design and implementation of control panel solutions for a wide range of industrial applications.

    Control Panel Design

    Our design team includes degreed engineering professionals to ensure that all panels are designed to meet the specific needs of the client.  We design panels with specific operational goals in mind, and with intense focus on safety, accuracy, value, and reliability. The design team provides factory acceptance test services based on customized FAT documents developed specifically for each application.

    Control Panel Manufacturing

    Design Group offers over 30 years of experience building high quality control panels and electrical control systems, and maintaining long-standing partnerships with leading technology suppliers. We offer technology solutions that best meet our client’s needs.  As one of the nation’s largest manufacturers of electrical control solutions, ControlTech Automation offers high value panels, short lead times, and exceptional quality.

    ControlTech Automation prides itself on expediting deliveries and meeting client deadlines. ControlTech maintains a multi-shift operation with a large staff of engineering professionals, designers, and electrical technicians. Our world-class manufacturing space is flexible to accommodate a wide range of projects and thus allows us to decrease lead times and expedite control panel deliveries without negatively impacting quality.

    Certifications and Inspections

    Following the latest in NEC guidelines

    • UL508A Self Certification for Domestic Control Assemblies
    • UL698A Self Certification for Hazardous Location Applications
    • CSA22.2 Self Certification for Shipments to Canada
    • International declaration of conformity
    • CE
    • ATEX
    • IECex
    • CCC (China)
    • 4.v. Gost (Russia)

    Project Management

    • Single point of contact
    • Project Specification
    • Schedule Development and Adherence
    • Parts Purchasing and Expediting
    • Detailed Design Review
    • FAT and Quality Control Assurance Coordination

    For more information on control panel solutions, visit ControlTech Automation.

  • Packaging Controls

    For over 30 years, Design Group has delivered successful automation projects to the world’s leading companies. We apply industry experience and expertise to deliver the most challenging and fast-paced automation and packaging applications.

    Our automation professionals combine a broad range of packaging experience and technical knowledge together with a disciplined execution methodology to deliver robust automation solutions across all industries.  For high-speed filling and packaging line solutions, Design Group implements industry leading technology platforms to deliver world-class solutions.

    Packaging Controls capabilities include:

    • Material Handling
    • Printing
    • Labeling
    • Inspection Systems
    • Secondary Packaging Requirements
    • Information and Performance Monitoring Systems
    • Machine Safety Controls

    Design Group provides complete turnkey production systems, line upgrades, and experienced professionals to complement the project team.

  • Process Controls

    Design Group process automation professionals combine a broad range of process experience and technical knowledge together with a disciplined execution methodology to deliver robust automation solutions across all industries. We deliver world-class ISA-S88 compliant batch solutions along with continuous process installations using industry leading technology.

    Process Controls capabilities include:

    • Project Management
    • Specification Documentation – URS, FS, DDS
    • Electrical Control System Design
    • Hardware and Instrumentation Specification
    • Control Panel Design
    • PLC, DCS and HMI Programming
    • Legacy System Migrations/Cross Platform Migration
    • Computer System Validation and Life Cycle Documentation
    • 21 CFR Part 11 Applications
    • Software Development to integrate enterprise management systems
    • SME Consulting:
      • Process System Studies and ROI Justification
      • Brewing
      • Beverage
      • Biologics
      • CIP/SIP Systems
      • CAPA/Deviation Mitigation
      • Material Handling
      • Dairy/PMO
      • Syrup Rooms
      • Ratio Blending
      • Product Genealogy
      • Water – WFI, USP-PW, RO/DI
      • Wine

    Design Group’s standard services include factory acceptance testing and simulation, installation management, start-up/commissioning, and validation and qualification activities where required. These services ensure the successful and timely implementation of all automation projects.

  • Information Solutions

    Design Group is a premier system integrator of information solutions with extensive experience in OEE, Enterprise Manufacturing Intelligence, Mobile Data Visualization, Process Historians, SCADA, Virtualization, and Network Architecture.

    We provide turnkey installations, software and hardware upgrades, and have experienced professionals ready to complement the client’s project team.  We maintain a robust competency certification program for our Information Solutions team, in order to ensure that our professionals are trained in the latest technology advancements.

    Our professionals apply their broad manufacturing software knowledge with leading-edge technologies and best practices to design and implement solutions that drive value to the client’s organization.

    We apply our industry experience to deliver against the most challenging applications and architectures.  We deliver successful solutions to the manufacturing industry’s leading companies.

    Information Solutions capabilities include:

    • SCADA
    • Process Historians
    • Mobile Data Visualization
    • Overall Equipment Efficiency (OEE)
    • Enterprise Manufacturing Intelligence
    • Manufacturing Execution Systems (MES)
    • Virtualization
    • Network Architecture
    • Reporting and Custom Applications
  • Cybersecurity

    Manufacturing is one of the most at-risk industries for ransomware attacks­­1, with breaches costing $3.6 million per incident on average and taking as many as 280 days to identify and respond to it.2

    Design Group’s cybersecurity experts combine deep domain expertise in a manufacturing environment with the latest technologies to implement a solution that brings the client to a sustainable and modernized state, saving ­­revenue, reputation, and data so often lost in cyberattacks. We strive to execute in accordance with the current industrial security standards on the manufacturing floor, minimizing the total cost of ownership and maximizing total data availability.

    Our Difference:

    • We are the conduit to convergence, allowing us to speak the language of both OT and IT and deliver the best possible outcome.
    • We consult and implement using master planning and a phased approach to allow for deeper security benefits to match capital budgets.
    • Cybersecurity infrastructure is built in from the beginning, not patched in later.
    • Our 400+ CSI professionals execute projects at the scale you need.


    • Cybersecurity assessment and remediation
    • Network design
    • Intrusion detection and prevention software implementation
    • Production hardware and software modernization
    • Computer hardening
    • On-going cybersecurity support (patching, administration, tuning)
    • Disaster Recovery
  • DG360

    DG360 is a 360⁰ operations support system to help you beyond project completion. Achieve a new level of operational success by optimizing productivity, reducing downtime, avoiding stoppages, creating efficiencies, and future-proofing your systems for innovation and growth.

    Learn More