Direct Automation is an automation integrator specializing in complex programming for the process industry.  We are platform independent, meaning we do not have alliances with any brand of automation, so you know you are getting the best automation for your needs.  We also work with non-proprietary equipment only, so you will never be forced into a continued relationship with us.

Our services are available as an add-on to your existing system or during a new installation.  Below are some of our more common requests from customers.


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Is your DCS in need of an update? Many systems are becoming Legacy, meaning it will be nearly impossible to find new parts or operating systems to run them, not to mention people that are familiar with the system to work on it.  Convert the legacy control system in your plant to a state of the art DCS with a better ROI, more control, less maintenance costs, more flexibility, friendlier user interface, and longer lifespan. Direct Automation offers a phased or a full conversion approach in order to work with your budget, schedule, and processing needs. Direct Automation has extensive experience in migrating legacy DCS installations in all on the following major platforms: Siemens Apacs, Rockwell/Allen Bradley, Schneider Modicon, ABB System 6, Foxboro and others. Call today to ask us about a Migration Plan that is customized to fit your plant’s needs.

Fill out this form to start the process of Direct Automation contacting you concerning your DCS Migration:  DCS Analysis Questionnaire

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Direct Automation creates sequencing packages for batch processes like fermentation and mash coolers. We can also create custom sequences to meet your needs. The benefits of fermentation sequencing will improve batch timing and reduce the variances to increase efficiencies and throughput. Direct Automation can integrate sequencing alongside your existing DCS for a bolt on solution that can be utilized even after a DCS Migration. The result of Direct Automation’s Sequencing is being consistently accurate on all of your batches. Direct Automation also offers monthly support after installation, give us a call and find your gap in production.

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Direct Automation is offering an advanced, fully-integrated, web-based information system which aggregates your data from virtually any part of your process and business, and makes it readily available via reports, dashboards, and KPI’s which are real-time, interactive, and view-able on your desktop, tablet, smart phone, or TV displays located strategically within your business. Data is collected automatically from systems such as your DCS, lab databases, operator logs, commodity systems, maintenance databases, and financial systems, and that data is then stored indefinitely and reported back to you in a web-based tool we call “PI in the Sky.” We will custom build interactive reports and KPI’s which provide instant insight into your business, which was previously available only through painstaking work of manually extracting and aggregating data on a case-by-case basis. All components of the system are hosted and managed by direct automation, so you never have to worry about replacing hardware or upgrading your software. Give us a call to see how PI in the Sky can help improve your operations.

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A large portion of the Advanced Process Control benefits can be better achieved by implementing control strategies with the tools on your current control system, however some complex logic just works better with APC. Now you can get “APC where you need it,” because Direct Automation provides a bolt on solution. Our bolt on APC can be implemented anywhere and be utilized even after a DCS migration. Automate processes, tune controllers, set alarms, and record data for every process imaginable. Reduce errors, inconsistencies, and down time to increase your bottom line and improve safety. We’ve saved 8% on annual natural gas usage for an ethanol plant on their grain dryers.  Discuss the opportunities with Direct Automation to find out how our APC services can fit your needs.

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Monitor your C-I-P system with acoustic monitoring. Acoustic monitoring will learn the sound of properly running spray balls and notify you when one starts to run poorly. This process provides an extra layer of security against batch infections. We can add this onto any current system.
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Have the same company that manages your automation IT networks manage your business IT networks.
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Sleep easy, Direct Automation’s approach to 24/7 service is to implement tools and preventative maintenance measures to head off unforeseen issues to minimize emergency support situations. We take a look at the control system infrastructure and identify weak links that can inhibit control system performance. You will receive reports on control system performance and areas for potential improvements. An experienced point of view you can count on can be a valuable resource. Direct Automation’s experienced programmers also have process experience that can help identify and implement control strategies to improve your plant’s process. Call at any hour, any day. Our qualified personnel are available when you need us. We offer the option for remote PC control to solve your problems. For emergencies, if needed, we can fly in and be at your plant in a matter of hours. Call us today to learn more.

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You don’t want to find out at the wrong time that a motor has failed. Give your maintenance managers more control and lead time with Wireless Machine Health. As a motor starts to vibrate poorly a message is sent to the DCS so that you can be ready with the parts you need…before a disaster strikes.

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Easily monitor and control parts of the plant that have traditionally been hard to access. Plant Wireless is a cost efficient way to add sensors in places that couldn’t previously be wired without the need for time consuming wiring. You can add sensors where and when you need them.


Include Direct Automation in the early stages of your project design to ensure automation is implemented to the best of its capacity. We can lighten the work load of your engineers by becoming the source of automation equipment and design. We can reveal opportunities for automation and control that we have real experience with. Once the project is complete, Direct Automation can stay on duty to ensure the project is successful and maintained.