Automation Solutions

 FGR Automation pioneers true edge-native predictive maintenance with EdgeAlyzer™ — the only fully standalone IIoT platform that performs real-time, AI-driven anomaly detection directly on the machine using Hailo-8 accelerated autoencoders. No cloud, no recurring fees, no IT dependencies. From single assets to plant-wide fleets, EdgeAlyzer delivers sub-3 ms fault detection, eliminates unplanned downtime, and turns vibration, temperature, and process data into actionable intelligence for manufacturing, processing, and critical infrastructure.

For four decades we have designed, built, and commissioned complete automation and control systems that run entire facilities. From PLC/SCADA architecture and HMI development to safety systems and hierarchical data management, we deliver robust, future-proof solutions using industry-standard platforms (Allen-Bradley, Siemens, Ignition, etc.) and modern systems-engineering practices.

Thirty eight complete coal and mineral preparation plants automated worldwide. Our systems control every stage — raw material receiving, crushing, washing, dense-medium separation, dewatering, and product load-out — with proven, data-driven designs that maximize throughput and recovery while minimizing operator intervention.

Forty high-speed material handling systems deployed. We specialize in batch-weighed and continuous train loading (including coupled-in-motion and flood loading), automated truck scales with manifest generation, stockpiling/reclaiming, and complex conveyor networks that keep tonnage moving 24/7 with ±0.5 % accuracy.

Veterans of PPG’s global “Blueprint for the Decade” program and numerous float lines worldwide. We automate batch houses, furnaces, tin baths, lehr control, transverse and edge cutting, stacking, and downstream fabrication — integrating robots, precision servos, vision systems, and hierarchical production/QC data systems.

Full instrumentation and control upgrades for coal, gas, biomass, and waste-to-energy plants. Boiler controls, turbine-generator synchronization, balance-of-plant automation, emissions monitoring, and fuel handling systems engineered for maximum availability and regulatory compliance.

Complete I&C packages for municipal and industrial water/wastewater plants. From raw water intake and filtration to biological treatment, chemical dosing, SCADA, and regulatory reporting — we deliver reliable, redundant systems that meet the strictest environmental standards.

 High-speed assembly line sequencing, robotic paint application, vision-guided quality inspection, and end-of-line testing systems for Tier 1 and OEM plants in North America, South America, and beyond.

Line-scan and area-scan vision solutions for defect detection, dimensional verification, surface inspection, and process guidance in glass, steel, packaging, pharmaceuticals, and automotive components — seamlessly integrated into new or existing control platforms.

Seamless upgrades of legacy Modicon, Allen-Bradley PLC-5/SLC, GE, or proprietary systems to modern platforms with zero downtime strategies. We manage the full lifecycle — planning, risk assessment, phased cutover, documentation, training, and long-term maintenance support.

FGR specializes in bespoke, safety-critical elevator systems for extreme applications. From the Porsche Design Tower’s three luxury auto-elevators (dual PM drives, ±3 mm accuracy, redundant safety PLCs) to NASA Kennedy Space Center’s Mobile Launcher 1 and VAB hoists — where we modernized 1960s-era massive elevators, integrated new DC drives, eliminated entrapments, and solved ultra-close landing challenges — we deliver precision and reliability when off-the-shelf solutions fail.

FGR Automation is a recognized expert in control system functional safety, designing and validating safety-related control systems to ISO 13849-1 Performance Level (PL) and IEC 61508 Safety Integrity Level (SIL) requirements. From redundant safety PLC architectures and safety-rated drives to light curtains, laser scanners, and emergency-stop circuits, we integrate modern safety technology without compromising productivity. With decades of field-proven safety implementations across high-risk industries — including NASA, automotive, glass, and bulk-material handling — we ensure your people, equipment, and operations are protected to the highest international standards.regulations.