Sterling Systems & Controls, Inc. specializes in delivering customized Products (Systems & Services) with integrated automation, process equipment, and process control for a wide range of applications in a variety of industries, including Feed, PetFood, Agriculture, Food, Baking, Rubber and many others. For over 45 years Sterling Systems & Controls has provided effective, efficient and reliable Products.

Contact us today to ensure that you get the results you expect and need!

Sterling Systems & Controls, Inc. offers Products (Systems & Services) solutions in the following areas:

Automation Software Upgrade

FreshStart™ – It’s New … Upgrading is Due!

What is FreshStart™?
Legacy software example

FreshStart™ is a technology program for automation software upgrade designed specifically for your Sterling Systems & Controls, Inc. legacy PC-based software.  Do you have automation software applications including batching, mixing, grinding and much more designed for and operating on MS-DOS, Windows XP, Windows 7, and Windows 8/8.1?  Your company or industry does not matter. If you currently use the state-of-the-art Microsoft .Net based software applications from Sterling Systems, great!  If not and you currently use our legacy PC-based software, the FreshStart technology upgrade is for you.

Reasons for Automation Software Upgrade

  1. Scalability.  The modular design of the Sterling Systems state-of-the-art SSCI .NET based software can easily grow as your manufacturing process grows which helps reduce automation software upgrade costs. This is not possible with your old legacy software (MS-DOS, Win XP, Win 7, Win 8/8.1 based).
  2. Various modules are available, currently including: Batching, Transfer, Receiving, Grinding, Pelleting, Loadout, Hand Prompt, Alarm & Events, PMPlanR™ Preventative Maintenance, and WebCentral™ Remote Supervisory Control and Web Access to Data.
  3. Software can run on Windows 10 Pro OS and future releases. Windows Server 2016 or later can be used. Web access can run on most modern browsers either on desktop or mobile devices. There is no chance of incompatibility issues in future releases.
  4. The latest and most state-of-the-art Microsoft and Allen Bradley technologies are used, thereby providing the latest security and the very best user experience and features possible.


Batching System Products

Sterling Systems & Controls, Inc. can provide Automatic and Semi-Automatic8 BIN MICRO SYSTEM Batching System products that will improve the efficiency of your powder and bulk, or liquid, material handling process. We specialize in custom designing, engineering, and manufacturing batching systems to increase your process performance, improve product consistency, eliminate product waste, and provide robust production data collection and reporting. Batching Systems can also include blending/mixing operations, and other process equipment, controls and automation. Batching Systems capabilities can include, but are not limited to:

  • Inventories unlimited number of materials
  • Tolerance control for accurate weights and batch integrity
  • Lot tracking & validation features
  • Multiple levels of security, password protection
  • Automation of material conveying/feeding devises (dry & liquid)
  • Prompting of hand add additions (systems with semi-automatic batching)
  • Automation of mixers
  • Automation of upstream and downstream equipment
  • Pneumatic & Mechanical conveyor automation
  • Multiple operating platforms (Software & Hardware)
  • Operator interface devises throughout the process with ergonomical designs
  • Enclosures available in stainless steel, mild steel or composite materials (NEMA rated)
  • Work stations/tables for platform scales, shelf to support other equipment such as printer, bar code readers and displays

Custom orders don’t upset us, we thrive on them! If you don’t see what you’re looking for, please don’t hesitate to contact us and ask, tell us how we can make the process system you need. Batching and weighing systems are oftentimes known by various terms, and we will gladly provide information on anything you may be looking for, such as: Batch Bulk Weighing Systems, Continuous Weighing Systems, Bulk Weigh Scale Systems, Micro-Systems/Micro-Ingredient Systems, Gain-In-Weight or Loss-In-Weight Batching Systems, Weigh Hopper and Batching Systems, Batching Control Systems, Minor/Micro/Major/Hybrid Ingredient Systems, and Liquid Weighing/Metering Systems.

Bearing Condition Monitor

Particle size reduction equipment is also known as grinders and classifiers.  These are milling machines of various types used to reduce the particle size of dry solids, such as grain and other granular materials.  These devices are rotating machinery. Sterling Systems & Controls, Inc. designs and manufactures the highest quality bearing condition monitor for use with the Prater Industries brand of high speed mills or classifiers. Various standard and optional features are available, including a choice of intrinsically safe bearing sensors for Prater equipment in hazardous areas. Intrinsically safe sensors are intended for use in the following hazardous area classifications:

• Class I, Div. 1, Groups A, B, C and D
• Class II, Div. 1, Groups E, F and G
• Class III, Div. 1
• Ex ia IIC T4 Ga
• Ex II 1 G
• Class I Zone 0 AEx/Ex ia IIC T4 Ta = -50°C to 120°C

The Control Panel for the Standalone Bearing Condition Monitoring systems is a NEMA 4X Fiberglass Enclosure with front door window kit and includes:
• Intrinsically Safe Barriers (if applicable) for accelerometer and temperature sensor outputs
• Digital Display Relay Modules & Display Controllers
• Clearly labeled and secure screw-type terminals for all external connections

Integrated systems are custom engineered and manufactured.  View more …..

Bulk Bag Packaging Systems Products

Sterling Systems & Controls has designed and manufactured bulk bag filling stationAUTOMATING BULK BAG FILLINGs for a wide range of applications. Whether as a standalone process or a part of an overall bulk material processing system, Sterling Systems bulk bag filling stations are custom designed to fit your exact process and to perform the way you need and want them to. Sterling Systems will also design and provide the automation and process control system for the entire bag filling operation, which can include a Motor Starter Process Control Panel with an Allen Bradley PLC (provides both discrete and analog outputs), an Allen Bradley Panel View Plus 10” color touchscreen, custom automation software including all M/O/A (Manual/Off/Automatic) switches with running indicating lights, four (4) motor starters, and all necessary fusing, wiring etc. to meet the application requirements.

Systems & Controls, Inc. bulk bag filling stations incorporate many of the same structural aspects as the micro, minor, and bulk weighing systems, but are specifically designed to efficiently and effective load/fill a bulk bag, usually at the end of the production process. Solutions are provided for filling bulk bags of dry bulk solid materials, and filling supply bins such as drums or tote tippers. Bulk bag filling stations can be combined with a variety of turnkey solutions for batching, mixing, conveying/transporting or, etc.. We design the bag filling stations within the physical constraints of your facility and can provide the controls as a standalone process, or as a part of the complete manufacturing process automation.

Bulk Bag Unloading System ProductsREDUCING DUST IN BULK BAG UNLOADER

Sterling Systems & Controls, Inc. offers a full line of Bulk Bag Unloading and Weighing Systems that incorporate many of the same structural aspects as the micro, minor, and bulk weighing systems, but are specifically designed to unload a bulk bag or tote, typically into a fixed hopper within the system.

Solutions are provided for unloading bulk bags of dry bulk solid materials and filling the supply bins such as drums or tote tippers. In addition, batch weighing can be added along with batching controls. These can include the addition of mechanical or pneumatic conveying, a choice of weighing solutions including gain-in-weight & loss-in-weight.

Bulk bag unloading systems that include weighing can be combined with a variety of turnkey solutions for conveying/transporting or dispensing the batch. These carefully selected solutions are used to convey/transport the product to the use points such as a day bin or mixer. Typical conveying systems include pneumatic & mechanical conveyors. Totes are commonly used where cross contamination or product degradation is a concern; both solid surface totes and flexible totes are used. A variety of bulk bag unloading and weighing systems installation configurations are possible, including allowing for the system to be mounted through a floor, or on a floor with legs.

Bag Filling Stations are also available from Sterling Systems & Controls, Inc.. We will design the bag filling station within the physical constraints of your facility and can provide the controls as a standalone process, or as a part of the complete manufacturing process automation.

Complete Systems

Sterling Systems & Controls, Inc. can bundle your milling, grinding, sifting, metal separation, and other process equipment into a complete process system. Our skilled and experienced engineers have in-depth knowledge of the process equipment and the technology devices required to properly operate your process from raw material feeding to final product destination. Sterling Systems & Controls, Inc. has developed strategic partnerships with industry leading equipment manufactures to be able to provide our customers with complete system design and integration.

Why struggle with sizing air movers, filter receivers, piping, and separation magnets while dealing with multiple suppliers when you can get it all from one source, Sterling Systems & Controls, Inc.? Our automation systems and process controls integration with a wide range of process equipment is second to none in the industry. We handle the following, and more:

  • System implementation and management
  • System design and process development
  • Mechanical process equipment, i.e. conveyors, mixers, grinders, etc.
  • Raw material receiving, material transfer, batching, mixing/blending, grinding/milling, screening, partical extruding, storage of finished product, bagging/packaging, loadout, and more
  • Lot tracking, material traceability and validation (RFID, Barcode, etc.)
  • Supervisory remote control, and integration with business systems

Data Management for Fracturing Sand Facilities

SandTrack™ is a software application that provides data management for fracturing sand facilities. It provides Inventory and Activity tracking for hydraulic fracturing sand storage and distribution facilities. It can also be used with any other types of sand distribution facilities. It integrates seamlessly with a Sterling Systems’ control system to provide data management and historical data logging for activities that occur through the control system. An optional Data Import/Export module can be included to provide a bridge between third party truck or railcar system, and the Sterling’ control system. This allows truck and railcar tickets to be imported from the third party system, serviced by the control system, and exported back to the third party system. SandTrack inventory data management for fracturing sand facilities application provides data management, historical data logging, ticket printing, management reports, and bridging between the aforementioned third-party and Sterling’ systems and the Sterling’ WebCentral™ remote supervisory application, as well as any remote Corporate Network and ERP system.

Feed Mill Automation

Pellet Mill Screen

Feed Mill automation can simplify operation and improve efficiency of cost and throughput. Sterling Systems & Controls, Inc. custom designs and manufactures the highest quality automation control systems for virtually any Feed Mill process or a complete facility. Regardless of the specific animal feed, cattle, poultry, swine, horse, Petfood, and more, Sterling Systems is “Your Premier Provider of Feed Mill / Petfood Production Solutions”.

Sterling Systems & Controls designs and provides standard equipment and customized software solutions for an overall customized feed manufacturing system (a.k.a. Feedmill system) using Allen-Bradley PLC’s and desktop PC’s running Sterling Systems’ customized Windows-based Automation Software.

Sterling’s forty-five plus (45+) years of process and automation experience ensures quality and efficiency in both hardware and software.  Software applications include:    READ MORE …..

Hand Prompt Batching Station

Sterling Systems & Controls, Inc. designs and manufactures Hand Prompt Station products (above picture shown with optional bag dump) to meet the specific requirements of each customer as needed. The Hand Prompt Batching Station serves a wide range of industrial applications where the negative effects of time consuming and problematic manual batching needs to be eliminated. The Hand Prompt Batching Station is a semi-automatic batching system that still requires operator involvement through each step in the batching process, but provides automated operator instructions or prompting, ingredient validation and lot tracking, automatic weighing with over/under tolerance control, etc. This system will eliminate bad batches that result from operator error and interruption. The operator no longer needs to keep track of where he is in the batching process, the automated Hand Prompt Batching Station does that for him automatically. No missed ingredients! No bad batches!

Material Weighing SystemsHand Adds

Sterling Systems & Controls, Inc. offers a variety of material weighing system products for many industries and applications. Each system is customized to meet the exact requirements and demands of our customer. Material Weighing Systems are useful for automatic batching or semi-automatic weighing using a single or multiple scales. A semi-automatic material weighing system requires operator assisted weighing with automatic operator instructions and lockouts to ensure there will be no more missed ingredients due to operator interuption.  This ensures batch integrity, quality & consistency (ingredient weighments within a programmable tolerance).

Common Material Weighing Systems Include:

Micro Weighing Systems

Sterling Systems & Controls, Inc. offers customized micro material weighing system products to weigh materials that require accurately measured ingredients that are critical to the batch integrity. These systems can be semi-automatic or automatic. With micro ingredient batching systems we offer supply bins, feeders, automatic bin refilling, work platforms, bag handling equipment, dust collection, and batched material conveying equipment (pneumatic and mechanical). Lot tracking, traceability and validation can be as simple or as comprehensive as you are prepared to implement.  And supervisory remote control is available with the use of our WebCentral supervisory control application.

Minor and Major Weighing Systems

sterling-material-weighing-systemOur unique approach to micro and minor ingredient weighing system products set us apart from typical systems. The designs are customized for each application utilizing standardized components. We offer Bulk Bag Weighing Systems, Ridged Tote Bin Systems, as well as Large and Small supply bin systems manufactured from Carbon Steel, Stainless Steel and Plastic. The scale designs are customized to minimize mass of the scale to insure high scale resolution while maximizing accuracy and repeatability.

The uniquely designed system shown here to the right features 18 supply bins and 4 scales with batching software for formulations, inventory tolerance control, lot tracking, and corp interface.

Preventative Maintenance Planning Software Products

Software Products are also developed and provided by Sterling Systems & Controls.  PMPlanR™ (pronounced “PM-Planer”) is a robust standalone Preventative Maintenance Planning Software Application. PMPlanR allows you to “Build Your Plant”. Within each Plant you can enter all Equipment Components (Areas or Machines) and Assets that should be monitored.

Process Controls and Automation Products

Sterling Systems & Controls, Inc. can match your specific equipment or process with the best process controls and automation system for your application. Our process experience and knowledge combines with our intimate familiarity with the latest control and automation components and software. We customize the solution to meet your exact requirements and needs. Whether you need to upgrade your present system to meet changing requirements, or need a fully automated control system for a new process application, we have the expertise in designing and building automation systems for customers worldwide.

Kitchen Batching System Products

Sterling Systems & Controls, Inc. provides many types of Products, including multiple types of batching systems. A popular type of batching system in many industries, but most especially in the food and related foodstuffs industries is the Semi-Automatic Batching System, a.k.a the Kitchen System. The semi-automatic batching system uses similar automation technology, both hardware and software, as the automatic batching systems. However, the semi-automatic batching system requires an operator to be present throughout the entire batching process to perform functions as detailed in the instructions provided by the semi-automatic system.

Supervisory Control Software Products

WebCentral is a browser-based supervisory control software application that allows you to access the database of a Sterling Systems control system. It allows you to do things like add or remove ingredients, create and manage recipes, manage ingredient and product inventories, setup a batching schedule, and review and print historical reports in a batching control system. Because WebCentral is browser-based, it is very simple and intuitive to use. This also means that WebCentral can be accessed by virtually any computer that is networked with the Sterling Systems batching or other type of control system, without having to install any software, other than a web browser. All features of WebCentral are protected with an elaborate, yet flexible, security scheme which is fully customizable. Does Accounting need to look up historical records, but they can’t modify recipes? What if your lab or corporate office needs to change recipes, but you don’t want them to change the batching schedule? No problem! WebCentral is a perfect fit for these and many other scenarios where a variety of individuals need access to information from your control system in a secure, reliable, and simple way.