Enhancing Operational Efficiency at Lycoming County Resource Management Services

At Martz Technologies, Inc. we excel at challenges, and our recent collaboration with Lycoming County Resource Management Services (LCRMS) demonstrates our expertise in Control Systems Integration. This project, valued at nearly $900,000, unfolded over a 12-month period, showcasing our company’s capabilities and commitment to excellence.

Scope of Work: Our collaboration with LCRMS included the replacement and startup of six fully automated Leachate Pump Control Panels, alongside their primary Leachate Pump House Control Panel. With a focus on process optimization and issue resolution, we provided level monitoring and flow monitoring equipment, and a plant wide network with Supervisory Control and Data Acquisition (SCADA) software.

Infrastructure Advancements: An essential aspect of this project entailed a fiber optic network upgrade, enabling real-time monitoring and control across the plant. Our team designed, installed, and tested over 12,000 feet of 24-strand single mode fiber optic cable, terminating all 720 LC fiber connectors across the campus. This infrastructure overhaul laid the groundwork for seamless SCADA integration, amplifying operational insights, and empowering LCRMS with enhanced control capabilities. Our collaboration with CoStream (formerly VZRscada) played a pivotal role in deploying a SCADA system, enhancing operational visibility, predictive analysis, and control.

Engineering Excellence: Our in-house team crafted a robust solution tailored to LCRMS’s needs. Over 250 pages of detailed AutoCAD drawings were created to guide the implementation process. Furthermore, our software developers mastered new PLC hardware platforms to deliver a solution that empowered plant operators with intuitive control and comprehensive plant oversight.

Acknowledgments: The success of this project extends from the dedication and expertise of our team members. Special recognition is due to Dan Zelazny, whose project management and design coordination ensured timely completion and client satisfaction. Likewise, Nathan Higgins deserves commendation for his proficiency in mastering new technologies and delivering a solid software solution.

Conclusion: At Martz Technologies, we take pride in our ability to tackle projects with diligence, teamwork, and integrity. Our approach, bolstered by a diverse team of professionals, positions us as a premier partner for automation solutions across industries.

White Flyer Targets, a leader in clay target manufacturing and now part of Winchester, recently partnered with Martz Technologies to modernize White Flyer’s oldest production line at its Pennsylvania facility. The existing control system, built on a decades-old Allen-Bradley PLC 5 platform, had become increasingly difficult to maintain. The plant’s motor control center (MCC) and communication infrastructure, which had been in operation for over 30 years, were in need of a comprehensive upgrade to improve efficiency, reliability, and scalability. 

The system in place consisted of 23 variable frequency drives (VFDs) ranging from 2 to 100 horsepower, multiple racks of PLC I/O scattered throughout the plant, and two aging PanelView 550 HMIs. The VFDs had been installed in an Allen- Bradley MCC over the past three decades and were controlled using an Allen-Bradley communication protocol from the early 1980s. Recognizing the need for a modern, high-performance automation solution, White Flyer turned to Martz Technologies for a complete controls and networking overhaul. 

Martz Technologies implemented a state-of-the-art upgrade, replacing all existing VFDs with the latest Allen-Bradley PowerFlex 755 and 525 models. The outdated PLC 5 system was migrated to a next-generation Allen-Bradley ControlLogix L81 safety processor, ensuring greater processing power, improved diagnostics, and enhanced safety compliance. The HMI systems were also upgraded to the latest 5510 series PanelViews, providing operators with an improved user interface and real-time system insights. 

A major component of this upgrade was the replacement of eight remote I/O racks with Allen-Bradley’s latest 5094 series Flex I/O, offering increased reliability and expanded control capabilities. The MCC, which had remained largely unchanged for decades, was completely overhauled and transformed into an Ethernet-based smart MCC, allowing for enhanced system monitoring, predictive maintenance, and improved troubleshooting. In addition to these critical control system upgrades, the plant’s process network was modernized with the installation of 42 industrial-grade network drops. Martz Technologies deployed 600V M.I.C.E. Level 3-rated Ethernet cabling, designed to withstand high electrical noise, extreme environmental conditions, and ingress, ensuring a high-performance, rugged, and future-proof network infrastructure. 

To execute this transformation, a dedicated four-man team meticulously reterminated over 800 points of I/O consisting of standard and safety-based I/O points, using a custom-designed 230 page AutoCAD Electrical Controls Drawing Package. This level of detail and precision ensured a seamless transition to the new system, minimizing disruption to operations while significantly improving the plant’s overall efficiency and reliability. 

With this comprehensive controls and network upgrade, White Flyer Targets now benefits from a cutting-edge automation system designed for long-term performance, scalability, and ease of maintenance. The modernization effort has not only improved system uptime but also provided a foundation for future expansions and industrial IoT capabilities. This project stands as another major accomplishment for Martz Technologies, demonstrating our commitment to delivering top-tier automation solutions that drive operational excellence.