Industrial Controls Engineering & Design

Custom control design and full system service for peace of mind

Put your operations ahead of the competition. Controls solutions enable individual system components to work together seamlessly through proper sequencing and coordination, reaching top-notch performance levels with programmed alerts for quick action. Depending on the application, controls systems can range in size and function. Our team of trusted engineers will help you choose the right industrial control solution for your project and quickly get it up and running.

The Bastian Solutions team provides complete controls solutions for machine automation and material handling systems. With a breadth of systems experience across many industries, we work together with systems project managers to pull together the best technologies and controls configurations for the optimization you need. Whether you have a new or existing system, regardless of size, we have the integration tools to connect them. These technologies must work together at their full capabilities for your operation to achieve maximum productivity. Coupled with control software and HMI, these systems provide complete, real-time visibility into your operations with status updates, statistics, and monitoring.

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See Controls Engineering & Design at Work


Prime Distribution

4 -1 Zipper


Becton Dickinson

Sawtooth & Double-sided Shoe Sorter


Southern Wine & Spirits

Puyallup, Washington


Engineering Design Expertise

Our abundance of industry experience and execution will get your controls system operational fast, allowing you the benefit of improved operations ahead of your competition.  Our clients come to us with confidence knowing that they will receive leading-edge quality and implementation that go beyond the confines of traditional engineering solutions. From new to existing equipment and from small conveying systems to fully automated industrial machines, let the expertise and capability of our engineers give you full control of your system.

Software Experience

  • AutoCad, RSLogix, FactoryTalk View, RSView, Siemens, and many more
  • Steeplechase update- a migration to Windows 7 from XP

Bastian Support Center

  • Conveyor system support
  • Maintenance and repairs
  • Troubleshooting and upgrades

Industries Served

  • Material Handling and Sortation Technologies
  • Food and Beverage
  • Apparel, Retail and General Commodities
  • Specialty Goods Handling (Chemicals, Pharmaceuticals, Parcel Services, etc.)
  • Robotics Automation
  • Security
  • Heat Treat and Manufacturing Processes
  • Automotive and Aerospace

Proposals & Documentation

Formal Proposals and Documentation

  • Minimized gaps between storage locations
  • Flexible layout – Build grid around pillars and other static obstacles
  • Applicable in low ceiling buildings
  • Decentralized warehousing possible
  • Gain of production space thanks to just-in-time delivery
  • Floor space usable as Servus runs under the ceiling
  • Ease of expansion

Functional Specification Documents

The first step in our controls system design process is to define the scope of the project for the customer; that includes:

  • System Functions (Material Hangling, Manufacturing, etc.)
  • Explicit Features (Application Specific)
  • Routing and Sortation of Products (Decision Points)
  • Operator Interfaces (HMI, PanelView, etc.)

After Bastian Solutions determines all the necessary project information, a Functional Specification Document (FSD) is created, including all project specifications, to be signed off by the customer and Bastian Solutions. This document ensures that customers’ needs are met and that Bastian has the necessary information to set a project schedule and allocate resources.

Controls Engineering Design

Hardware Design

Bastian Solutions begins its controls engineering process by designing the electrical layout of your system and panels utilizing a variety of industrial drawing tools (i.e. AutoCAD, Siemens ePlan, etc.).  Based on the customer’s specifications, our Controls Engineers will determine the most efficient electrical configuration and design necessary to achieve maximum productivity from your system.

Software Design

Our Controls Engineers understand that each project is different.  With our broad range of controls software experience, Bastian Solutions then determines a software design solution that meets your project specifications (i.e. RSLogix, Siemens Step-7, etc.)

Panel Build

After your system design drawings have been verified and finalized by our Controls Engineers, our in-houseUL & ULC Certified panel shop’s technicians will build and test the necessary Motor Control and Field Panels essential to running your system.

PLC and HMI Programming

Bastian Solutions has a vast amount of experience in the programming of its controls and HMI systems.  With this in mind, that experience has established quick and efficient development of PLC and HMI programs because of proven modules custom to each specific application.  Programming is completed prior to going on-site so that our Controls Engineers can begin troubleshooting your system immediately. 

PLC or Sophisticated PC Based Systems

Bastian Controls offers both PLC and Sophisticated PC based control systems depending upon your application or specifications.  Both our PLC and PC code use standard (proven) logic routines to bring about an extremely reliable immediate solution.


Commission the system

Onsite troubleshooting and employee training will occur until the system is fully implemented.  Upon the completion of Final Acceptance Testing (FAT) and reaching customer specific beneficial use, Bastian Solutions then hands over system operations to the end user.  Bastian prides itself on the level of support we can provide throughout the entire process of system commissioning: before, during, and after the completion of your project.

  • Define ERP (Enterprise Resource Planning)
  • Client/Server Interfaces (HMI):
    Our HMI, or Human-Machine Interface, is a GUI (graphical user interface) that allows your operator to seamlessly interact with and control your system simply by using a typical mouse and keyboard.  In this complex world of industrial and material handling controls systems, our HMI gives each customer the added advantage of reduced down time, more effective troubleshooting, and real life system perspective.
  • Interface with Real-Time routing and status updates
  • Exacta Software Integration:
    Bastian Solutions has the capability of interfacing and integrating with existing WCS programs.  In addition, Bastian Solutions offers its own ExactaWCS: Warehouse Control System software as a suitable alternative; giving the customer flexibility to pick choose based on their specific needs.

Post Go-Live Support

Every customer receives 24/7 Support for one (1) year following the commissioning of their system.  Bastian Solutions’ quick-support dispatch is dedicated to getting your system functional and efficient as quickly as possible; if any problems should arise.  Once system support expires, we offer a number of support packages to keep your system running to its best capability.


Engineering Design resources

  • panel-solutions-for-many-industries
  • panels-manufactured-by-our-experts
  • panels-built-to-operate-your-system
  • specializing-in-custom-panel-solutions
  • custom-control-panel-solutions
  • hmi-conveyor-status-screen
  • hmi-screen-pallet-building
  • hmi-screenshot-of-mezzanine
  • hmi-screen-scanners-scales-stats
  • master-control-station
  • system-controls-with-zipline-amp-perfect-pick
  • control-panel
  • engineering-autocad-design
  • system-controls-for-retail-conveyor
  • controls-hmi-screen
  • controls-story
  • controls-story3
  • controls-story2
  • controls_header

Related literature

Controls Brochure (pdf)

Interested in engineering design or want to know more about it?​