How to Choose the Best System Integrator for Your Material Handling Project (Compared)

Selecting a system integrator determines how effectively a material handling project moves from concept to production. The selection affects controls architecture, conveyor performance, operator access, documentation, commissioning, maintenance, and future expansion.

A qualified integrator should address the complete control system: not isolated programming tasks. Evaluation should cover:

Material handling experience
Conveyor control engineering
PLC and HMI platforms
Electrical panel design
Safety systems
Network and software integration
Project execution
Commissioning
Long-term support

Conveying Controls L.L.C. provides electrical control systems for conveyor and material handling applications, including full system concept and design, procurement and specification services, schematic drawings, FLA calculations, PLC-based controls, HMI platforms, and customer support. With more than 35 years of experience, the company supports projects from initial concept through system delivery.

DEFINE THE PROJECT SCOPE

Begin the comparison before requesting proposals. Each integrator should receive the same project information.

Document the following:

Conveyor types
Conveyor lengths and elevations
Product dimensions and weights
Required throughput
Accumulation requirements
Sortation requirements
Motor quantities and horsepower
Existing PLC and HMI platforms
Facility electrical requirements
Network requirements
Safety requirements
WMS, ERP, or production-system interfaces
Expansion requirements
Required production date

A project brief prevents incomplete proposals. It also allows each integrator to identify design constraints before pricing and scheduling.

A greenfield installation may require complete controls architecture, panel construction, field wiring, and commissioning. A retrofit may require PLC migration, HMI replacement, field-device compatibility, and phased installation around active production.

The selected integrator should have experience with the specific project condition.

COMPARE MATERIAL HANDLING EXPERIENCE

General automation experience does not automatically equal material handling expertise. Conveyor systems require coordinated control of motors, sensors, zones, merges, transfers, accumulation logic, diverters, and emergency-stop circuits.

Request project examples involving:

Conveyor lines
Distribution centers
Manufacturing plants
Case handling
Pallet handling
Sortation
Accumulation
Packaging interfaces
Conveyor retrofits
Multi-zone control systems

Review the scope of each reference project. A supplier that only programs a PLC may not provide the electrical engineering, panel design, field integration, or commissioning required for a complete system.

A true material handling system integrator should coordinate the interaction between mechanical equipment, electrical controls, operator interfaces, safety devices, and facility systems. Integrated-system providers commonly distinguish turnkey project execution from equipment-only supply. The Integrated Systems overview from Conveyor Handling Company provides an example of this project model.

EVALUATE PLC ENGINEERING

The PLC controls the operating sequence and coordinates the equipment. Poor PLC structure creates maintenance delays, troubleshooting difficulty, and future modification risk.

Request information about:

PLC manufacturer and platform
Processor capacity
I/O architecture
Remote I/O requirements
Industrial Ethernet or fieldbus network
Program structure
Tag naming standards
Alarm logic
Fault recovery
Manual and automatic operating modes
Version control
Backup procedures
Source-code delivery
Documentation standards

The integrator should explain how the program will control conveyor zones, detect jams, manage accumulation, coordinate product transfers, and restart equipment after a fault.

The proposal should also identify the party responsible for PLC programming, electrical design, panel construction, field installation, and startup. Responsibilities divided between multiple vendors require formal coordination.

Conveying Controls focuses on PLC-based platforms for conveyor and machine control systems. The scope can include control concept development, control wiring schematics, component specifications, procurement support, and system documentation.

REVIEW HMI DESIGN AND DIAGNOSTICS

The HMI is the primary operating and diagnostic interface. A functional HMI should provide direct access to machine status and fault information.

Evaluate the proposed HMI design for:

Conveyor status
Motor status
Zone status
Sensor status
Active alarms
Alarm history
Fault location
Manual controls
Reset functions
Maintenance screens
User permissions
Production counters
System modes
Network status

Ask the integrator to demonstrate a typical alarm sequence. The demonstration should show how an operator identifies the affected zone, confirms the fault, and returns the system to operation.

Avoid HMI designs that display only generic messages such as “Conveyor Fault.” The interface should identify the equipment, condition, and required maintenance action when possible.

HMI standards should be defined before programming begins. Late-stage screen changes can affect testing, operator training, and commissioning schedules.

ASSESS ELECTRICAL ENGINEERING AND PANEL CAPABILITY

The control panel houses the equipment that powers and controls the system. Panel layout affects heat management, maintenance access, troubleshooting time, and future modifications.

Request the following deliverables:

Electrical schematics
Panel layout drawings
Power distribution drawings
Control circuit drawings
I/O schedules
Terminal schedules
Network drawings
Wire numbers
Component lists
Spare-parts lists
FLA calculations
Panel test documentation

Review panel construction examples for:

Wire organization
Component labeling
Terminal accessibility
Circuit protection
Drive spacing
Cooling provisions
Separation of power and control wiring
Spare capacity
Documentation storage

Conveying Controls provides schematic drawings for machine control wiring, conveyor control wiring, and panel control wiring. FLA calculations and special project requests can be incorporated into the design process.

CONFIRM SAFETY ENGINEERING

Safety requirements must be included in the initial design. Retrofitting safety devices after controls development can create schedule changes and unplanned field work.

Discuss:

Emergency-stop circuits
Guard-door interlocks
Pull-cord switches
Light curtains
Safety relays
Safety PLC requirements
Reset locations
Lockout/tagout access
Safety zones
Restart prevention
Risk-assessment responsibilities
Validation documentation

Clarify which party supplies safety devices and which party develops the control logic. Confirm how safety circuits interact with conveyor zones, drives, motors, and upstream or downstream equipment.

The project documentation should identify safety devices by location and function. Operators and maintenance personnel require clear procedures for reset, inspection, and restart.

REVIEW INTEGRATION REQUIREMENTS

Material handling automation frequently connects to other systems. The controls integrator should define the interface between the conveyor system and external equipment or software.

Potential interfaces include:

WMS
WES
ERP
Barcode scanners
Vision systems
Robotics
Packaging equipment
Production systems
Building systems
Remote monitoring platforms

Ask for the proposed communication method, data ownership, interface testing process, and fault-handling procedure.

The integrator should identify:

Required data points
Message structure
Network responsibilities
Interface testing dates
Simulation requirements
Communication-loss behavior
Recovery procedures
Cybersecurity responsibilities

A controls system should continue to operate in a defined state when communication with an external system is interrupted. The recovery sequence should be tested before production release.

COMPARE PROJECT EXECUTION

Technical capability is only one selection factor. Project execution determines whether the design reaches production according to the required schedule.

Request a project plan containing:

Design milestones
Submittal dates
Drawing-review dates
Procurement dates
Panel-build dates
Factory acceptance testing
Installation dates
Field checkout
Commissioning
Operator training
Documentation delivery
Warranty start date

Identify the project manager and technical lead. Confirm the communication frequency and format for schedule updates, risks, submittals, change orders, and open issues.

The integrator should define the factory acceptance test before the test occurs. FAT procedures may include I/O verification, motor rotation, safety-circuit testing, alarm testing, HMI review, network checks, and sequence testing.

VERIFY SUPPORT AND DOCUMENTATION

Material handling systems require support after startup. Evaluate the integrator’s post-installation process before contract award.

Confirm availability of:

Remote technical support
On-site service
Spare parts
PLC backups
HMI backups
Electrical drawings
Network documentation
Training
Preventive maintenance guidance
Software-change support
System expansion support

Define response times, support hours, escalation procedures, and warranty coverage.

Documentation should be delivered in usable formats. Include final PLC programs, HMI files, as-built drawings, manuals, component lists, network diagrams, and test records.

USE A WEIGHTED COMPARISON MATRIX

Use the same scoring system for each finalist. A five-point scale provides a simple comparison.

Evaluation Category	Suggested Weight
Material handling experience	20%
PLC and HMI capability	20%
Electrical engineering and panel design	15%
Safety and network integration	10%
Project management	15%
Commissioning and testing	10%
Service and documentation	10%

Score each integrator against documented requirements. Do not allow a low initial price to offset missing controls scope, incomplete documentation, or limited support.

Compare total project value, including:

Engineering
Components
Panel construction
Programming
Installation
Commissioning
Training
Spares
Warranty
Future modifications

SELECT THE INTEGRATOR THAT OWNS THE CONTROL RESULT

The best system integrator is not necessarily the lowest bidder. Selection should prioritize relevant experience, defined responsibility, maintainable controls, complete documentation, and reliable support.

Before award, confirm that the integrator can:

Design the control concept
Develop the PLC architecture
Configure the HMI
Produce electrical schematics
Specify and procure components
Build or coordinate control panels
Integrate conveyor equipment
Test safety circuits
Complete commissioning
Train operating personnel
Support future changes

Conveying Controls L.L.C. applies more than 35 years of conveyor and material handling experience to PLC- and HMI-based control projects. Review the available services at www.conveyingcontrols.com, define the project requirements, and request a structured controls evaluation.

COMPARE. DEFINE. VERIFY. SELECT.