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Client: Leading Manufacturer of Pyrolysis Machinery
Client Type: OEM
Industry: Waste-to-Energy / Renewable Energy
Location: UK
Scope: Turnkey control and automation system integration for containerised pyrolysis plant
Seamless integration of multi-manufacturer equipment into a unified control system
Certified functional safety to EN13849 standards, validated by TÜV-certified engineers
Enhanced cybersecurity with secure remote access for diagnostics and maintenance
Cloud-based data management using AWS for analytics and traceability
Rapid deployment through a fully containerised plug & play solution
“The quality of engineering was first class, and iconsys’ attention to detail made the integration a complete success.”
— Plant Manager, Pyrolysis Plant
This project transformed a brownfield site into a state-of-the-art, containerised waste-to-energy plant for a leading manufacturer of pyrolysis machinery.
The client’s innovative technology converts diverse waste streams into biochar, a valuable recycled product that supports sustainable, circular waste management.
iconsys designed and delivered the complete master control and safety system, combining advanced automation, functional safety and digital connectivity within a containerised format.
Our TÜV-certified safety engineers followed an approved methodology from concept to validation, ensuring full traceability and certification at every stage.
1. Integrated, containerised control system
The entire automation solution was housed within a containerised, plug & play control unit, allowing for rapid installation and easy scalability for future sites.
iconsys engineered the PLC and SCADA software to manage multiple communication protocols across the plant’s subsystems. The Siemens S7 Safety PLC provided certified safety-rated control in accordance with the client’s Safety Requirement Specification (SRS).
2. Safe, secure and connected operations
A Siemens Industrial DMZ firewall protected the network, with a dedicated DMZ router enabling remote engineering access for diagnostics and updates without interrupting operations.
Process data was captured locally and securely transferred to AWS for cloud-based analytics, providing both traceability and performance insight.
The functional safety system, designed to EN13849 standards, included:
Emergency stop circuits for immediate shutdown
Safety-rated pressure, temperature and level sensors
Safety dump valves to prevent pressure or material build-up
Integration of safety I/O through the Siemens S7 network
All stages, from Machine Design Risk Assessment (MDRA) and Safety Requirement Specification (SRS) to Design, Verification, FAT, SAT and Validation (FT & FIT), were documented and verified under iconsys’s TÜV-approved process.
3. Unified equipment control
iconsys integrated a range of complex process equipment into a single, cohesive control environment, including:
Conveyors for feedstock transfer
Pyrolysis kiln for waste-to-biochar conversion
Burners for precise heat management
Coolers for syngas temperature control
Abatement filter for toxin removal and clean emissions
Continuous Emissions Monitoring Systems (CEMS) for real-time exhaust monitoring and automatic safety shutdown
iconsys delivered a fully integrated, functionally safe and digitally connected automation solution that set a new benchmark in containerised waste-to-energy design.
By combining automation, functional safety, and digital connectivity, iconsys enabled the client to accelerate the delivery of a sustainable and efficient waste-to-energy platform.
The client selected iconsys for our proven multi-vendor integration expertise, TÜV-certified functional safety capability, and ability to deliver secure, connected automation systems that meet modern standards for digital manufacturing.
Our end-to-end approach ensured a safe, efficient and future-ready waste-to-energy facility, setting a new industry benchmark in integrated plant automation.
The quality of engineering was first class; each phase of the project was completed in a professional and timely manner.
The complexity of this installation project undertaken by iconsys can’t be underestimated. It involved several heavy-duty tasks as well as some very intricate wiring work, which was completed on time over several weeks.
Their professionalism, preparation and attention to detail when integrating the new Kiln, coolers, panels and additional onsite equipment to enable cross communication throughout the facility was a complete success.
I was very impressed with iconsys from the start. A big thank you to the iconsys team.
— Plant Manager, Pyrolysis Plant
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