Material Handling Automation
Reliable, Scalable Automation for Material Handling & Logistics Systems
Material handling operations depend on high availability, accurate control, and seamless integration across conveyors, sortation systems, and automated handling equipment. Downtime, bottlenecks, or poorly integrated control systems can quickly impact throughput, safety, and service levels.
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Stratos Control Systems delivers robust, standards-based material handling automation solutions designed to improve reliability, enhance system visibility, and support scalable growth. We work closely with engineering, operations, and maintenance teams to ensure handling systems perform consistently and can be supported long term.
Automation Designed for Complex Material Handling Systems​
Material handling systems often involve multiple machines, control zones, and interfaces, operating continuously and at high throughput. Legacy PLCs, inconsistent standards, or limited diagnostics can make fault finding difficult and increase operational risk.
Stratos Control Systems designs, upgrades, and supports material handling automation systems that are:
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Highly reliable and fault tolerant
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Easy to diagnose and maintain
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Scalable for system expansion
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Integrated across multiple subsystems
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Our focus is on practical system-wide automation, not isolated machine control.
Typical Material Handling Automation Challenges
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We are frequently engaged to address challenges such as:
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Downtime caused by control system failures
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Bottlenecks and throughput limitations
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Poor system-wide visibility and diagnostics
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Difficult integration between conveyors, sorters, and subsystems
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Ageing or unsupported PLC hardware
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Inconsistent control standards across zones or lines
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By addressing these challenges at the control system level, we help material handling operations improve reliability and performance.
Our Material Handling Automation Services
Control Panel Design & Build
We design and build industrial control panels for material handling applications using AutoCAD and E-Plan, focusing on clarity, safety, and maintainability.
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Control panel design and build
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Conveyor and system control panels
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Panel refurbishment and upgrades
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Clear labelling and full documentation
PLC Programming & System Control
We deliver PLC programming and system control solutions for material handling systems of all sizes and complexity.
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PLC programming and upgrades
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Zone-based and system-wide control
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Integration with drives, motors, and safety systems
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Structured, supportable PLC software
SCADA, HMI & System Monitoring
Visibility is critical in material handling environments. We design SCADA and HMI systems that provide system-wide insight and fast fault resolution.
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SCADA system design and integration
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Centralised monitoring and control
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Alarm management and diagnostics
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Trends and performance monitoring
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Platforms including Ignition, WinCC, InTouch, FactoryTalk View SE
Material Handling System Upgrades & Refurbishment
We modernise heavy engineering automation systems while minimising operational risk.
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Obsolete PLC and SCADA replacement
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Control panel refurbishment
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Automation system modernisation
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Phased upgrades for migration strategies.
Integration & Expansion Support
Material handling systems often evolve over time. We support system expansion and integration with minimal risk.
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Integration of new conveyors or zones
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System expansion planning
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Standardisation across existing systems
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Improved diagnostics and documentation
Automation Platforms We Support
Stratos Control Systems primarily delivers material handling automation solutions using trusted industrial platforms:
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Siemens
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Allen Bradley
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Mitsubishi
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We also support a wide range of legacy and specialist control systems, particularly in long-established handling environments.
Material Handling Applications We Support
Our material handling automation experience includes:
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Conveyor and sortation systems
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Automated storage and retrieval systems (AS/RS)
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Distribution and logistics facilities
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Manufacturing material flow systems
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Integrated production and handling lines
Why Choose Stratos Control Systems for Material Handling Automation
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Experience delivering complex system-wide automation
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Strong focus on reliability, diagnostics, and scalability
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Expertise across PLC, HMI, SCADA, and control panels
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Proven capability upgrading live material handling systems
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Practical, site-focused engineering approach
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We deliver material handling automation systems that keep goods moving efficiently and reliably.
The Result
Improved throughput. Faster fault resolution. Reduced downtime.
Material handling automation systems designed for continuous, reliable operation.
Talk to Us About Material Handling Automation
Whether you are upgrading legacy control systems, improving system visibility, or expanding material handling capacity, Stratos Control Systems can help.
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Discuss a Material Handling Automation Project
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Speak to engineers experienced in material handling automation environments.