Drives and Control Magazine

Unlocking Efficiency and Mitigating Risk:

What Do Systems Integrators Actually Do?

In the fast-paced world of UK manufacturing, terms like “digital transformation,” “Industry 4.0,” and “automation” are everywhere. But behind the high-level strategies and board-level discussions, who actually bridges the gap between raw hardware, complex software, and your day-to-day production goals?

The answer lies with systems integrators (SIs).

Recently, Nikesh Mistry, Sector Head for Industrial Automation at GAMBICA (the premier trade association for the UK automation and control sector), sat down with our very own Sales and Marketing Director, Ian Clarke, to demystify the role of an SI. The interview, featured prominently in Drives and Controls Magazine, dives deep into how professional integration keeps factories running, handles legacy risks, and acts as the true launchpad for digital transformation.

Here are the key takeaways from their conversation and what they mean for your plant’s operational resilience.

1. De-Risking the Upgrade: Phased Migrations over “Big Bangs”
   One of the most significant anxieties for Plant Managers and Engineering Directors is dealing with ageing, mixed-vendor environments. When critical hardware faces obsolescence, the fear of extended, unplanned downtime during an upgrade often causes businesses to delay vital maintenance.

As Ian Clarke points out, a professional systems integrator doesn’t just replace parts blindly; they carefully strategise to eliminate risk:

“We handle this by carefully picking systems within a factory and upgrading them in a phased or partial way – selecting which system will introduce the least risk during commissioning, but overcomes the greatest risks of failure.“

Ian Clarke, Sales & Marketing Director, inControl

By utilising proven off-site testing environments and employing reversible commissioning practices, inControl Systems ensures that if an unexpected issue arises before a scheduled line start-up, the factory can safely revert to its original state. This systematic approach delivers peace of mind alongside upgraded reliability.

2. The “Double Win“ of Tackling Obsolescence
   A common disconnect in manufacturing lies between C-suite digital ambitions and the reality of the factory floor. While executives want advanced data analytics, engineering teams are often nursing obsolete PLC or SCADA setups just to keep the lines running.

Rather than viewing legacy hardware as a burden, inControl sees it as an incredible opportunity for a “double win”:

“Our view is that running a business on obsolete hardware is far too often neglected and should be given greater attention and investment… By upgrading systems with future digitalisation methods and IT/OT architecture, you can not only avoid unplanned downtime from old equipment failing, but also be a springboard to starting a site-wide industrial digitalisation programme.”

By addressing the immediate threat of obsolescence, you simultaneously build the robust IT/OT infrastructure needed to capture, analyze, and leverage your production data.

3. Bridging the IT/OT Gap for Real Process Data
   True digital transformation isn’t an off-the-shelf software purchase. It relies entirely on extracting clean, reliable data from physical machines—whether that is tracking energy consumption, monitoring machine performance, or ensuring product quality traceability.

However, because most UK manufacturing facilities feature equipment of varying ages and origins, unlocking that data requires a rare blend of legacy operational technology (OT) knowledge and modern IT capability.

“To get this data is not as simple as plugging a network cable into a control panel… a wide set of IT and OT skills are needed to be able to connect to machine control systems and sensors in order to monitor and sometimes control what’s going on in production.”

4. Calm Heads and Real-World Experience
   Industrial automation rarely happens in a vacuum, and real-world commissioning occasionally throws up unexpected process variables. When a system leaves a clean testing bay and enters a complex, live factory environment, things don’t always react as predicted on paper.

When unexpected challenges occur, the value of an experienced partner becomes clear:

“Control engineers can never be expected to understand every process out there, but experienced engineers and communication usually save the day.”

Ian emphasises that having “calm heads,” deep engineering expertise, and an open, collaborative relationship with the client is what ultimately turns complex process engineering challenges into successful, high-yielding outcomes.

Put inControl of Your Systems

At inControl Systems, we have spent over 25 years acting as a trusted partner to the manufacturing, food and beverage, and process industries. We don’t just supply software or build panels; we deliver scalable, turnkey solutions—from initial consultation and electrical design through to commissioning and long-term support.

If you are currently managing the risks of obsolete hardware, looking to integrate mixed-vendor assets, or trying to unlock actionable data from your plant floor, let’s talk.

Contact us today for an initial consultation to discuss your systems integration needs and find out how we can help optimize your efficiency, productivity, and peace of mind.