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Services / Automation & Control
Automation & Control Mackay

PLC Programming - Mackay & Bowen Basin
Reliable logic from engineers who've worked the sites.

We design, write and commission PLC programs for mining, sugar, manufacturing and utilities across Central Queensland. Allen-Bradley ControlLogix, CompactLogix, Siemens S7 and Beckhoff TwinCAT.

PLC Programming

What plc programming with Beetle actually looks like.

What we deliver

Our PLC programming service covers the full project lifecycle - from functional design specification (FDS) through to factory acceptance testing (FAT), site commissioning and handover documentation.

Every program we write follows a consistent, structured standard so your maintenance team can read and modify it without needing us in the room.

Our programming approach

We write PLC code to be maintainable by your site electricians, not just by the programmer who wrote it. That means:

  • Descriptive tag naming that matches your P&ID
  • Structured ladder logic with clear rungs and comments where the logic is non-obvious
  • Alarm management built in from the start, not bolted on at the end
  • Version-controlled backups delivered with every project

Typical project types

Greenfield systems - new equipment or processing lines, from I/O design through to full commissioning.

Control system upgrades - replacing end-of-life PLCs (PLC-5, SLC 500, S5) with modern equivalents while preserving the process knowledge locked in the old code.

Modifications and extensions - adding new I/O, updating sequences, integrating new instruments or drives into an existing system.

Fault response - diagnosing and resolving production-stopping faults, often remotely but always available to attend site.

Rockwell
Siemens
Beckhoff

One process. Zero surprises.

Scoping
  • Site walk & asset review
  • Requirements capture
  • Network & OT audit (if required)
Quoting
  • Scope of work definition
  • Deliverables schedule
  • Fixed-price or T&M proposal
Optional
Upfront engineering
  • Concept design & review
  • Feasibility & risk assessment
  • Design basis document
Documentation
  • Functional descriptions
  • Electrical drawings & diagrams
  • Network & architecture diagrams
  • IO lists
  • ITC / test sheets
  • Asset & network audits
Programming
  • PLC programs (Studio 5000 / RSLogix)
  • SCADA & HMI development
  • FactoryTalk / CitechSCADA / Aveva
  • OT network configuration
FAT → SAT & commissioning
  • Factory acceptance testing (FAT)
  • Site acceptance testing (SAT)
  • Loop checks & punch-list close-out
  • Hand-back & as-built documentation
All industries →
case study image

Mackay Sugar PLC Migration — 36h Hand-back

36-hour planned outage. Zero overruns. System handed back to operators 2 hours inside the window with all interlocks verified and documented.

Sugar Mills Rockwell ControlLogixStudio 5000
Read the case study →

Common questions, straight answers.

We primarily work with Rockwell Automation (ControlLogix, CompactLogix, MicroLogix), Siemens (S7-300, S7-400, S7-1500), and Beckhoff TwinCAT. We also have experience with Schneider Electric Modicon and GE/Emerson platforms.
Yes. A significant part of our work is upgrading or extending legacy systems - PLC-5, SLC 500, S5, and similar platforms. We document existing logic before any changes and plan cutovers to minimise production impact.
Yes. We offer on-call support contracts and scheduled maintenance visits. Most clients in the Bowen Basin retain us for shutdown support and ad-hoc fault response.

Pairs well with

Beetle rewrote our entire crusher control logic during a 10-day shutdown. Clean code, proper documentation, no surprises on startup.
Electrical Superintendent Bowen Basin Coal Operations

Ready to discuss your plc programming project?

Talk to an RPEQ engineer about your project. We work across mining, sugar, manufacturing and utilities throughout Queensland.