When a Northern Michigan manufacturer needed to replace an unreliable emissions monitoring system, they partnered with Feyen Zylstra to implement a new automation and controls solution that would improve data visibility, ensure regulatory compliance, and provide long‑term reliability. The existing system had become inconsistent and ultimately stopped functioning, leaving the customer without a dependable way to monitor and record volatile organic compound (VOC) emissions required by environmental regulations. 

Feyen Zylstra delivered a fully integrated solution built from the ground up, replacing legacy hardware and software with a modern control system designed to meet current operational needs while supporting future expansion. The system features a centrally located control panel with distributed I/O, enabling efficient communication between monitoring points throughout the plant. By leveraging an Allen‑Bradley CompactLogix PLC, FactoryTalk Optix HMI, and Point I/O, the new platform provides a reliable and flexible foundation for capturing, displaying, and storing emissions data. 

The upgraded system allows operators to view both live and historical data directly through the HMI, giving the customer immediate insight into system performance and emissions levels. Daily data backups are automatically saved to local storage, with the ability to expand to server‑based archiving in the future. Built‑in alarms notify personnel of any monitoring failures, including data collection interruptions or sensor issues, helping ensure issues are identified and addressed quickly. 

Feyen Zylstra supported every phase of the project through a design‑build approach, including control panel design and inhouse fabrication, PLC and HMI programming, industrial networking, and data collection development. A key technical challenge was developing reliable data‑tracking logic that met the customer’s specific monitoring and record‑keeping requirements. This was addressed through extensive system development and testing offsite, allowing the team to refine performance before deployment and ensure a smooth onsite startup. 

Since implementation, the customer has gained a reliable, compliant system that supports consistent emissions monitoring and record retention. Improved data visibility enables better operational awareness, while alarm notifications and system diagnostics reduce the risk of undetected failures. The platform also positions the customer for future growth, allowing additional monitoring points and data types to be easily integrated into the system while maintaining centralized control and reporting. 

The success of the project was driven by close collaboration between Feyen Zylstra’s engineering, panel shop, and electrical service teams, along with the customer’s operations staff. By designing the system with scalability and long‑term usability in mind, the solution delivers lasting value and supports the customer’s ongoing compliance and operational goals.