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What We Do: PLC & Control Systems Services

Hexar Solutions works with manufacturers, facilities managers, mining operators, and infrastructure owners who need reliable, code-compliant automation and control systems. We don’t sub out the programming to a third party — our licensed electricians carry out the full scope of work, from design and panel fabrication through to site installation, testing, and commissioning.

Our core capabilities in Brisbane and surrounding areas include:

• PLC programming and configuration — Siemens, Allen-Bradley (Rockwell), Omron, Mitsubishi, Schneider Electric, and Beckhoff platforms
• Control panel design and fabrication — designed to AS/NZS 3000 and AS/NZS 60204 standards, with full documentation packages
• SCADA system installation and integration — including Ignition, WonderWare, and FactoryTalk environments
• VSD (Variable Speed Drive) installation and commissioning — across a wide range of manufacturers including ABB, Danfoss, Rockwell, and Siemens
• Motor control centres (MCCs) — new builds, upgrades, and replacements
• Field instrumentation and process control — sensors, transmitters, actuators, and field wiring
• Legacy PLC upgrades and migrations — replacing end-of-life hardware without disrupting production
• Fault-finding and breakdown response — for existing control systems that need rapid diagnosis

Typical Project Scope: What to Expect

Every automation project is different, but most control system engagements follow a similar process. Understanding what’s involved helps you plan realistic timelines and budgets — and avoids the cost blowouts that come from scope creep.

Design and Documentation

Before any cable goes in, we produce a full engineering package — including schematic drawings, I/O lists, cable schedules, and equipment datasheets. For projects involving machine safety or hazardous areas, this documentation forms part of your compliance record. All panel designs reference AS/NZS 60204 (Safety of Machinery — Electrical Equipment of Machines), which sets out requirements for control panel construction, wiring, marking, and protection coordination.

Panel Fabrication and Field Installation

Control panels can be built in our workshop in Wynnum prior to installation, reducing on-site time and minimising disruption to your operations. Field installation includes all conduit, cable tray, instrumentation wiring, and earthing in accordance with AS/NZS 3000 (the Australian Wiring Rules). We work in operating plants and can schedule around shutdowns or production windows where required.

Programming, Commissioning, and Handover

PLC programming is carried out by our own team — we don’t hand that scope off to a separate software house. This means one point of accountability for the whole project. Commissioning includes functional testing against your process requirements, loop checks, and operator training where needed. You receive as-built drawings, program backups, and a commissioning report as part of every job.

Industries We Work With in Brisbane

Brisbane’s industrial base is diverse, and our team has worked across most of the sectors active in South East Queensland. Relevant experience includes:

• Food and beverage manufacturing — including hygienic-area wiring requirements
• Water and wastewater infrastructure — pump station automation, SCADA telemetry, and remote monitoring
• Materials handling and logistics — conveyor control, sortation systems, and warehouse automation
• Chemical and process plants — including hazardous area (Ex) installations
• Commercial and industrial building services — BMS integration and energy metering
• Mining and resources supply chain facilities — robust control systems for demanding environments

We hold ISO 9001 quality management certification and are members of NECA (National Electrical and Communications Association), which means your project is backed by a formal quality system and an industry body with enforceable standards of practice.

Frequently Asked Questions

What’s the difference between a PLC programmer and a PLC electrician?

A PLC programmer writes and configures the software logic that controls your process. A licensed PLC electrician can do both — carry out the physical electrical installation and write the program. In Australia, all wiring work must be performed by a licensed electrical contractor. Hexar Solutions employs licensed electricians who are also qualified in automation programming, so you’re not managing two separate contractors or dealing with gaps in accountability when something doesn’t work correctly.

Which PLC brands does Hexar Solutions work with?

Our team has hands-on experience across the platforms most commonly found in Australian industry, including Siemens (S7-300, S7-400, S7-1200, S7-1500), Allen-Bradley / Rockwell (MicroLogix, CompactLogix, ControlLogix), Mitsubishi (FX and Q series), Omron, Schneider Electric (Modicon), and Beckhoff TwinCAT. If you have an existing installation on a platform not listed here, contact us on 1300 365 700 and we’ll advise whether we can support it.

Can you upgrade our old PLC without shutting down our production line?

In many cases, yes — but it depends on your process and the extent of the hardware changes required. Our approach to legacy PLC migrations starts with a detailed audit of the existing system, including documentation of any undocumented logic. We then develop a migration plan that stages the changeover to minimise downtime, often working through planned shutdowns or low-production periods. We’ve completed migrations on live production facilities across Brisbane and regional Queensland where zero unplanned downtime was a hard requirement.

What Australian standards apply to control panel and PLC installations?

The two primary standards are AS/NZS 3000 (Wiring Rules), which covers all electrical installation work including control wiring, earthing, and protection, and AS/NZS 60204 (Safety of Machinery — Electrical Equipment), which specifically addresses the design and construction of electrical equipment on machines and plant. Depending on the application, additional standards may also apply — such as those covering hazardous areas, functional safety (IEC 61511 / IEC 62061), or network communications. All Hexar Solutions installations are fully code-compliant and documented accordingly.

Do you provide SCADA integration alongside PLC work?

Yes. SCADA integration is a regular part of our project scope. We work with common SCADA platforms including Ignition (Inductive Automation), AVEVA (WonderWare), Rockwell FactoryTalk, and Citect. This includes configuring communications between the PLC and SCADA server, building operator screens, configuring alarms and historian tags, and testing end-to-end data flow. We can also assist with remote access and telemetry setups for unmanned sites such as pump stations or remote substations across the Brisbane and South East Queensland region.

What areas around Brisbane do you service?

We’re based in Wynnum, Brisbane, and regularly take on projects across the greater Brisbane metro area including Moreton Bay, Logan, Ipswich, Redlands, and surrounding industrial corridors. We also work on projects nationally through our licensed operations in QLD, NSW, VIC, SA, and WA. For projects outside greater Brisbane, contact us to discuss logistics and mobilisation. Call 1300 365 700 or visit hexarsolutions.com.au for more information.

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