Client: CBI Manufacturing
Industry: Oilfield & Agricultural Equipment Manufacturing
Location: Western Canada
Project Type: Shot Blast Booth Control System Modernization
Scope: Controls Assessment | PLC Programming | Control Panel Fabrication | Installation | Commissioning
Project Overview
CBI Manufacturing operates shot blast booths as a critical part of their production process for oilfield and agricultural equipment. Over time, their existing blast and solenoid control system became increasingly unreliable, difficult to service, and costly to maintain. What initially appeared to be a routine repair quickly exposed deeper issues with system architecture and long-term supportability.
The core challenge was vendor lock-in. The original equipment manufacturer relied on proprietary hardware, software, and an HMI platform that was no longer well supported. Replacement components were expensive, lead times were uncertain, and even minor repairs required specialized access. The system had already undergone a previous repair, but it was clear that continuing down that path would only increase risk and downtime.
CBI Manufacturing needed a solution that addressed not just the immediate failures, but the long-term reliability and serviceability of their blast booth operation.
Identifying the Challenge
A full evaluation of the blast booth control system revealed an overly complex and fragile setup. Proprietary components limited repair options, while aging hardware increased the likelihood of unplanned downtime. Each failure carried production risk, and every repair raised questions about how long the system would remain viable.
Rather than recommending another temporary fix, Current Group stepped back to assess how the system functioned as a whole and what would be required to create a sustainable, long-term solution.
Engineering a Better Approach
Current Group determined the most effective path forward was a complete rebuild of the control system using a modern, PLC-based architecture. This approach removed the dependency on proprietary platforms and replaced it with an open, industry-standard control system designed for reliability, transparency, and long-term flexibility.
The new design focused on creating a system that could be easily understood, serviced, and expanded in the future. Key priorities included improving uptime, simplifying troubleshooting, and ensuring the system could be supported by any qualified controls technician, not just a single vendor.
Once the design was finalized, the project moved into execution. Our team developed and tested the PLC control logic, fabricated a new PLC control panel in-house, and bench-tested the entire system prior to installation. This ensured a smooth transition during on-site commissioning and minimized disruption to CBI’s operations.
Before
After
The Solution
The original shot blast booth control system was fully replaced with a custom-built, PLC-based control panel tailored specifically to CBI Manufacturing’s process requirements. The new system delivers reliable blast and solenoid control through open, non-proprietary programming and clearly documented logic.
By eliminating vendor lock-in, CBI now has full control over their equipment. Parts availability is no longer restricted, future modifications are straightforward, and service costs are significantly reduced. The system is adaptable, transparent, and designed to evolve alongside the facility’s production needs.
Results & Impact
The modernization project delivered clear, long-term benefits across reliability, cost control, and operational confidence.
| Project Focus | Outcome |
|---|---|
| Vendor Dependency | Eliminated proprietary hardware and software |
| Maintenance Costs | Reduced long-term repair and support expenses |
| System Reliability | Improved uptime and consistent operation |
| Serviceability | Open PLC platform accessible to qualified technicians |
| Future Flexibility | Easy modifications and upgrades as needs change |
| Operational Confidence | Reliable, supportable blast booth for years to come |
Business Impact
This project demonstrates how modern control system upgrades can deliver far more value than simple repairs. By rethinking system architecture and replacing proprietary controls with an open PLC platform, Current Group transformed a recurring maintenance issue into a durable operational asset.
For manufacturers facing aging equipment, unsupported control systems, or rising maintenance costs, there is often a smarter path forward. A well-engineered modernization can reduce risk, improve reliability, and restore confidence in critical production systems.
If your facility is dealing with similar challenges, Current Group can help assess your options and design a control solution built for long-term performance. Ready to take the next step? Contact us today to get started.
