What are HMI’s?
HMI refers to the interface that allows human operators to interact with machines and equipment in a user-friendly way. HMIs display real-time data, production metrics, alarms, and enable control of devices through intuitive screens.
Modern HMI screens empower operators to manage operations effectively, from straightforward tasks like viewing a single machine’s status to complex automation sequences across an entire plant.
What is SCADA Systems?
SCADA refers to an entire system that provides high-level monitoring and control over industrial processes. It includes sensors, PLCs/RTUs, communication networks, central software, and operator workstations.
SCADA’s primary role is supervisory – it acquires data from processes in real time and allows operators to monitor and control equipment from a central location without being physically present.
While an HMI is focused on visualising information and providing a means to input commands, a SCADA system is the entire control system that might include many HMIs as well as data logging, networking, and automation capabilities beyond just the user interface.
In fact, an HMI is usually a component of a SCADA system. SCADA not only displays data but also typically collects and stores data in databases, runs control logic, and coordinates large-scale operations.
Key Capabilities of HMI/SCADA Systems
Real-Time Monitoring
HMI/SCADA systems provide live visibility into machine and process status, showing current values of sensors (temperatures, pressures, speeds) and the state of devices (pumps, valves, motors).
Operators can see hundreds or thousands of data points across a plant displayed in organised, intuitive graphical formats for immediate awareness of conditions.
Data Acquisition & Logging
SCADA continuously gathers data from sensors and instruments and stores this information in a historical database (historian) for analysis and troubleshooting.
Trend data over time helps identify patterns, performance issues, or gradual changes in the process, and creates an audit trail for compliance and reporting purposes.
Automation & Control Logic
SCADA can supervise higher-level logic beyond basic PLC control, coordinating multiple machines or phases of a process through scripts, batch sequences, or recipes.
This ability to automate multi-step processes boosts consistency and frees operators from manual control of routine tasks.
Supervisory Control
Operators can issue commands to start/stop machines, open/close valves, adjust setpoints, or execute other control actions remotely without physically accessing the equipment.
A single operator can control multiple processes or an entire plant from one central station, enhancing efficiency and reducing staffing requirements.
Alarm Management
When monitored values cross predefined thresholds, the system triggers alarms through visual cues, audible signals, and notifications to ensure critical conditions are addressed promptly.
Modern systems can send SMS, email, or mobile app alerts to relevant personnel even when they are not in the control room, improving response times to issues.
Reporting & Analytics
Generate production reports, quality reports, batch records, and other documentation using historical data, with charts and summaries of key performance indicators.
Modern systems incorporate analytics to identify trends, inefficiencies, or anomalies, helping predict maintenance needs and optimise processes.
Our HMI/SCADA Solutions
At Sull Systems, we deliver comprehensive HMI/SCADA solutions tailored to your specific manufacturing needs. Our expertise spans from small machine-level HMIs to complex plant-wide SCADA implementations.
Custom HMI Development
We design intuitive, user-friendly operator interfaces that make complex processes easy to monitor and control:
Graphical displays with clear visualisation of process data
High-performance HMI design principles for improved situation awareness
Digital twin implementation for simulation and optimisation
Multi-language support and role-based access control
SCADA System Implementation
We implement robust SCADA systems that provide comprehensive monitoring and control of your industrial processes
PLC/RTU integration and communication setup
Historian configuration for data logging and trend analysis
Alarm management systems with notification capabilities
Recipe management and batch control functionality
Reporting tools for production, quality, and compliance
System redundancy for high availability
Advanced Analytics and IIoT Solutions
Enhance your SCADA with modern capabilities that drive continuous improvement:
Predictive maintenance solutions using machine learning
OEE (Overall Equipment Effectiveness) monitoring
Energy management and consumption tracking
Quality analytics and SPC (Statistical Process Control)
Digital twin implementation for simulation and optimisation
Integration Services
Our integration expertise connects your HMI/SCADA with other business and manufacturing systems:
MES (Manufacturing Execution System) integration
OPC UA and other standard protocol implementation
Legacy system integration and modernisation
IIoT (Industrial Internet of Things) enablement
Why Choose Sull Systems?
Vendor-Independent Approach: We work with all major PLC and SCADA platforms (Siemens, Rockwell, Schneider, etc.) to provide the best solution for your needs.
Full Lifecycle Support: From initial concept through design, implementation, commissioning, and ongoing maintenance.
Modern Standards: We implement solutions based on the latest industry standards and best practices for security, usability, and performance.
Integration Expertise: Our team excels at connecting diverse systems and equipment into cohesive, manageable solutions.
Future-Ready Design: We build systems that can evolve with your business, incorporating new technologies as they become available.
Our CIP software solutions help you achieve consistent cleaning results. They minimise resource usage and reduce downtime. Our solutions also guarantee full compliance with industry regulations.
Key Capabilities of HMI/SCADA Systems
Improved Operational Efficiency
Automate data collection and equipment control to streamline operations. Operators can supervise multiple processes simultaneously, and automated control ensures optimal setpoints are maintained continuously.
Our clients typically report increased OEE (Overall Equipment Effectiveness) and reduced scrap rates after implementing our solutions
Enhanced Quality and Consistency
Ensure processes run within specified parameters consistently, improving product quality and reducing variability. Recipes and setpoints stored in SCADA guarantee consistent execution of production runs.
Full traceability through historical data allows thorough investigation of any quality issues that arise.
Remote Access
Monitor and control your processes from anywhere with secure remote access. Plant managers can check operations from home, and on-call engineers can respond to issues without travelling to site.
This flexibility improves response times and reduces downtime during off-hours.
Greater Visibility and Insight
Gain complete visibility into your entire operation from the plant floor to the executive level. Real-time dashboards highlight issues immediately, while historical trends reveal opportunities for process improvement.
Make data-driven decisions based on comprehensive information rather than assumptions or incomplete data.
Increased Safety
Monitor equipment continuously to detect hazardous conditions and take automatic action to prevent accidents. Reduce operator exposure to dangerous environments by enabling remote monitoring and control.
Software interlocks prevent unsafe operations and guide operators with clear procedures and warnings
Meets Industry Guidelines
Automatically log all relevant process information and generate compliance reports for auditors. Prove that processes remained within allowed limits and that proper procedures were followed.
Simplify obtaining and maintaining certifications like ISO standards through comprehensive data collection and reporting.
Industries We Serve
Our HMI/SCADA solutions are deployed across diverse industries with specific requirements:
Food & Beverage
We implement SCADA systems that control Clean-in-Place (CIP) systems, batch processing, and packaging lines while ensuring food safety and traceability. Our solutions help maintain consistent product quality and comply with food safety regulations.
Pharmaceutical & Life Sciences
Our validated SCADA systems for pharmaceutical manufacturing manage batch recipes and maintain strict environmental conditions. Every batch’s conditions are recorded to generate reports for quality release and regulatory compliance.
Discrete Manufacturing
For assembly lines and other discrete manufacturing, our SCADA systems coordinate conveyors, robots, and machine cells to maintain production flow. We help you track OEE, reduce changeover times, and identify bottlenecks.
Process Industries
In continuous process industries, our solutions monitor and control complex processes with numerous variables. We implement advanced process control strategies and ensure tight integration between all process units.
Utilities & Energy
We design SCADA systems for monitoring and controlling energy distribution, water treatment, and utility services. Our solutions help optimise energy usage and manage critical infrastructure reliably.
Welcome To Sull Systems 