Metals

iconsys helps metals producers extend asset life, cut energy costs and maintain safe, compliant operations through engineered automation and control modernisation.

Find out how we can help your business

Engineering reliable, high-performance automation for the metals industry

Metals producers face rising costs and tighter margins. Energy price volatility, ageing control systems and complex compliance demands make it difficult to maintain throughput without major capital spend.

Common challenges:

Unplanned downtime and rising maintenance cost from obsolete systems
High energy consumption and carbon-related levies
Safety and cyber incidents disrupting operations
Limited visibility of real production performance

iconsys delivers engineered automation that provides measurable ROI, extending asset life, improving energy performance and reducing unplanned downtime.

Balancing performance, cost and compliance in metals manufacturing

Rising energy prices, ageing control systems and the demand for safer, more sustainable production are reshaping the metals industry.

For plant operators and engineers, the challenge is maintaining output while keeping costs, risks and downtime under control.

iconsys helps manufacturers meet these challenges through proven automation and control expertise, delivering projects that improve reliability, safety and overall efficiency.

Our approach:

Vendor-independent, platform-agnostic integration
Lifecycle design: concept, migration, commissioning, support
Quantified performance targets: uptime, energy, safety, cost

iconsys have completed 400+ metals projects across steel, aluminium and non-ferrous sectors

How we make it happen

Extend asset life & defer replacement

We modernise legacy drives, PLCs and control systems in planned phases to avoid the disruption of full replacements.
Our migration strategies retain existing infrastructure wherever practical, reducing capital expenditure and engineering risk.
Each upgrade is engineered for long-term supportability, helping metals producers maintain performance and plant availability.

Reduce energy and emissions cost

Intelligent control of furnaces, rolling lines and drives helps optimise power use and reduce wasted energy.
Integrated monitoring gives operators visibility of energy trends and opportunities for improvement.
By improving process efficiency, we help metals manufacturers lower operating costs and progress toward sustainability targets.

Protect uptime and compliance budgets

iconsys designs and validates safety systems to recognised international standards, protecting people and equipment.
Functional safety solutions such as interlocks, emergency stops and safety PLCs minimise the risk of costly incidents.
We support clients through every stage of the safety lifecycle, ensuring compliance and peace of mind during operations.

Prevent costly production disruption

Our defence-in-depth approach safeguards industrial networks from external and internal threats.
We implement segmented architectures, controlled user access and secure communication between OT and IT systems.
By aligning with established OT cyber frameworks, we help metals producers maintain system integrity and operational continuity.

Enable insight for continuous ROI

Once automation foundations are modernised, connected systems capture valuable production and maintenance data.
We design information flows that support better planning, faster fault diagnosis and ongoing performance gains.
This readiness ensures our clients can scale towards analytics and optimisation at their own pace.

Why work with iconsys

iconsys combines multi-vendor integration expertise with deep process understanding.
We design automation solutions that fit your infrastructure, not a specific technology, helping you achieve safer, smarter and more reliable metals production.

What makes us different:

A single expert partner for the entire industrial automation lifecycle
Technology-independent solutions tailored to each customer’s requirements
Mechatronic expertise with integrated mechanical design and product supply
Comprehensive service and support, covering every stage from design to long-term operation
Modular, scalable and future-ready systems engineered to grow with your needs
Proven capability in resolving complex challenges, including obsolescence, safety and integration issues
Award-winning, multi-disciplinary UK team supported by our own manufacturing facility
Strong global customer base spanning end users, OEMs and EPCs
Cross-sector automation knowledge, ensuring best-practice solutions from a wide range of industries
Reliable global project delivery with consistent quality and execution standards

Contact our metals team

Don’t let capital expenditure concerns hold you back…

Capital expenditure on industrial assets can often be a stumbling block to obtaining the automation you need within your business. We offer flexible financing options to ensure you can get your automation project off the ground straight away.

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