Continuous wire and cable production demands precise synchronization, tension control, and stable extrusion performance. Many facilities operate legacy Siemens PLC platforms and aging drive systems on equipment supplied by global OEMs such as Niehoff, Lesmo, North Hampton, Davis Standard, Roteq, Nokia Maillefer, and other European and North American machinery manufacturers.
As these systems age, obsolescence, drive failures, and limited diagnostics introduce operational risk and production instability.
Integrity Control Services (ICS) delivers engineered controls modernization, Siemens PLC support, and turnkey automation upgrades for wire and cable manufacturers—improving reliability, maintainability, and long-term plant performance.
Wire and cable lines rely on coordinated multi-drive systems, dancer feedback loops, and synchronized extrusion and winding processes.
Legacy controls increase risk in several ways:
Modernizing controls stabilizes line speed, improves quality, and standardizes your automation architecture for future growth.
• Unplanned downtime from failing PLCs and drives
• Difficulty sourcing obsolete Siemens components
• Inconsistent tension control leading to scrap
• Limited diagnostics and poor visibility into line performance
• Challenges integrating with plant-wide SCADA and reporting systems
ICS has supported wire and cable manufacturers for more than 15 years. Our engineers understand both the control architecture and the mechanical process dynamics unique to wire production.
Applications supported include:
• Extruder and jacketing lines
• Insulation lines
• Capstans (servo and VFD controlled)
• Payoffs and takeups
• Traversing winders
• Multiwire lines
• Bunchers
• Cablers
• Dancer arm tension control systems
• Diameter compensation and reel change sequencing
We understand the synchronization requirements between extruders, capstans, bunchers, and takeups—and how improper tuning or outdated hardware impacts product consistency.
ICS has experience supporting, troubleshooting, and modernizing automation on machinery from major wire and cable OEMs, including:
Many of these lines were designed with Siemens PLCs and Profibus/Profinet drive networks. ICS has deep experience maintaining these systems or converting them to Allen-Bradley ControlLogix platforms when corporate standards require.
Insight into your data allows you to pinpoint problems, understand the efficiency of your process, and discover your ind your optimal production rates.
Accommodate new machinery, change your automation equipment, or align with new industry technology.
Accelerate growth with a visual representation of what’s happening on the manufacturing floor.
A neutral vendor to build your panels to your exact specifications.
Keep costs low by repairing machinery over replacing.
Stay up-to-date on automation technologies and increase your performance quality with expert-led on-site classes.
ICS supports both Siemens and Allen-Bradley architectures.
Siemens Modernization:
• Upgrade legacy S5 or early S7 processors
• Modernize TIA Portal environments
• Replace obsolete I/O and communication modules
• Improve diagnostics and alarm structure
Allen-Bradley Conversion:
• Siemens-to-ControlLogix migrations
• Ethernet/IP network redesign
• FactoryTalk View HMI upgrades
• Structured, tag-based program architecture
Our vendor-neutral approach ensures the selected solution aligns with your maintenance strategy and long-term plant standards.
A modernization project may include:
• PLC hardware replacement or migration
• Drive upgrades (DC to AC VFD or servo systems)
• Network modernization (Ethernet/IP, Profinet)
• HMI redesign with enhanced diagnostics
• Tension loop and dancer feedback optimization
• Temperature control system upgrades
• Safety circuit redesign and compliance improvements
• Integration with plant SCADA or MES systems
Projects can be executed as complete turnkey upgrades or phased retrofits to minimize production disruption.
ICS engineers execute structured program migrations and optimizations that preserve line functionality while improving maintainability.
Whether modernizing a Niehoff buncher, upgrading a Maillefer extrusion line, or converting a legacy Siemens-based cabling system to Allen-Bradley, ICS ensures operational integrity and improved performance.
ICS operates a UL508A-certified panel shop in Richardson, Texas.
For wire and cable projects, we provide:
• Custom extruder and line control panels
• Drive retrofit cabinets
• Remote I/O panels
• Safety-rated enclosures
• Factory Acceptance Testing prior to shipment
• Complete as-built documentation
Engineering is completed using AutoCAD Electrical or EPLAN to meet customer standards.
Wire and cable plants operate continuously.
ICS provides 24/7/365 field service for:
• Siemens PLC troubleshooting
• Allen-Bradley systems
• Servo and VFD diagnostics
• Profibus, Profinet, and Ethernet/IP communications
• HMI and SCADA troubleshooting
• Emergency drive replacement and startup support
Our focus is rapid restoration of production combined with root cause analysis to prevent recurring failures.
Aging wire and cable automation systems increase downtime risk and reduce operational flexibility. ICS provides a structured, technically sound modernization path that protects production today and prepares your facility for future expansion.
Contact Integrity Control Services to discuss your wire and cable manufacturing automation needs with an experienced engineering team.
Talk with one of our senior engineers and we’ll identify the problems you’re facing.
Working with your timing, budget, and existing equipment, our experts will work to find a solution unique to your industry.
No longer doing more of the same, reduce downtime, increase production, and deliver better results.
Integrity Control Services
Automation implementation, integration, and maintenance for any industry.
DALLAS/FORT WORTH METRO OFFICE
972-943-1101
885 E. Collins Blvd., Ste 103 Richardson, TX 75081
HOUSTON METRO OFFICE
281-866-0848
22001 Northpark Suite 800
Kingwood, TX 77339
MECHANICAL DIVISION
469-910-3255
681 Eastgate Road, Suite 1
Midlothian, TX 76065
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