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Client: Leading Aluminium Manufacturer
Industry: Metals / Aluminium Processing
Location: Bridgnorth, Shropshire, UK
Scope: Electrical design, manufacture, and commissioning of two aluminium foil mills
Modern, reliable and maintainable drive and control system
Faster line speeds and higher production throughput
Improved quality and process consistency
Enhanced data visibility and management information
Scalable design supporting future digitalisation
“The new systems designed by iconsys will facilitate improved production capacity, faster speeds and enhanced management information.”
— Engineering Manager, Aluminium Manufacturer
As part of an £11 million improvement programme, a leading aluminium manufacturer in Bridgnorth sought to modernise two ageing aluminium foil mills.
With global demand for aluminium foil increasing, the company required a full electrical design, manufacture, and commissioning package that would deliver state-of-the-art performance.
The new systems needed to enable faster line speeds, greater production efficiency, and consistent product quality, while providing a solid foundation for future automation and data-driven improvements.
iconsys completely redesigned the electrical and control systems for both foil mills, implementing a modern architecture based on Siemens S7 PLC technology with Profibus-DP and TCP/IP local area network communications.
The control system was designed around two core PLC platforms:
The motor control PLC, interfacing directly with all line AC and DC drives via its own Profibus-DP network, also managing line pumps and fans through discrete I/O.
The common control PLC (CC), integrating the wider plant operation — including operator stations, proxies, solenoids and encoders — via a second Profibus-DP system.
A central operator pulpit formed the hub of the new system, featuring three 21-inch display monitors mounted above the main viewing window for real-time process visibility. Two ergonomically designed operator desks provided access to all manual and automatic line functions, ensuring intuitive operation and streamlined workflow.
The project successfully transformed both aluminium foil mills, delivering measurable improvements in productivity, reliability and control.
Modern, efficient and maintainable drive and control platform
Faster line speeds delivering increased production throughput
Enhanced process consistency and foil quality
Detailed management information enabling better operational oversight
Future-ready infrastructure aligned with the client’s long-term automation strategy
iconsys’ deep experience in industrial automation, motion control and systems integration ensured a seamless upgrade of both foil mills. The modern Siemens-based solution not only improved day-to-day operations but also positioned the client to embrace future digital transformation, enabling smarter, more connected manufacturing.
This project exemplifies iconsys’ ability to deliver turnkey control and automation upgrades that drive performance, quality and competitive advantage in demanding manufacturing environments.
“The new systems designed by iconsys will facilitate the improved production capacity of the mills with increased throughput, faster speeds and detailed management information. Collective enhancements will also now enable us to address the worldwide market for aluminium foil products more competitively, with consistent quality and improved customer service.”
— Engineering Manager, Aluminium Manufacturer
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