A02
Engineering & Specification
Functional specification, safety matrix, hardware selection, network planning to NAMUR — the basis everyone refers back to later.
Services
Field-proven automation solutions
From PLC programming through commissioning to retrofit, program recovery and AI consulting – engineering services for modern production lines in the Saar-Lor-Lux region.
Scope of services
Three areas, one point of contact. Channels with a branch lead to the full description.
Automation
Control, visualization, drives and commissioning — from the functional specification to acceptance.
A01
Control Retrofit & Migration
S5 and S7-Classic to S7-1500 or S7-1200, WinCC Flexible and Comfort to Unified. The plant keeps running; the changeover happens in the shutdown window.
View serviceA03
PLC Programming
TIA Portal for S7-1200/1500 (incl. F), STEP 7 Classic for S7-300/400 (incl. F). Structured to IEC 61131, ProfiSafe included.
View serviceA04
HMI & SCADA
WinCC Comfort, Advanced and Unified. Faceplates, recipe management, alarm archive, multilingual operator interfaces.
View serviceA05
Drive Technology
SINAMICS, SEW and Danfoss via PROFIdrive. Positioning, synchronization, servo axes.
A06
Process Control
PID loops for pressure, temperature, flow and level. Process optimization and quality assurance.
A07
Commissioning & Service
On-site commissioning worldwide, function testing, acceptance, operator training. Experience on four continents.
View serviceA08
Program Recovery & Reverse Engineering
When all that remains is an online snapshot without symbols: re-documentation from the running system, reconstruction from scanned circuit diagrams.
A09
PLC & Visualization for Panel Builders
You supply the cabinet and the installation, I supply the program, visualization, system test and commissioning. Your customer gets one complete project.
View serviceOT Security
Securing the automation layer up to the boundary with the office network. Corporate IT is not part of it.
B01
Zone and Cell Segmentation
Network structure of the automation layer, separation of individual plant cells and a controlled transition to the office network — instead of a flat network where every controller reaches every other.
B02
Remote Maintenance and Remote Access
A connection the plant establishes outbound, released on site instead of standing permanently open. Over cellular where no plant network is available — with a site assessment beforehand rather than trial and error.
B03
Hardening Controllers and Visualization
User and permission concept, firmware and patch levels, shutting down services that are not needed. Plus technical groundwork for NIS2 requirements at plant level.
Data Paths & AI
Making what the plant produces usable — in analysis, in reports, in the ERP.
C01
Plant Data & OPC UA
Opening up data sources in the controller and passing them upward cleanly — OPC UA, MQTT, database.
View serviceC02
AI Workflows from Production Data
Fault and downtime analysis, shift and maintenance schedules, machine data into ERP or dashboard.
C03
AI-Assisted Engineering
In daily use, not in a test setup: TIA Openness workflows, AI-assisted re-documentation, machine evaluation of technical documents.
From planning to acceptance
8 Steps for Successful Project Execution
- S1
Engineering & Specification
Functional Design Specification (FDS): Specify plant function, integrate safety matrix, automation concept (P&ID), verify hardware compatibility
- S2
PLC Programming
Siemens TIA Portal / STEP 7 Classic, F-programming for safety functions, structured programming in STL/FBD/LAD/SCL, hardware configuration and network setup
- S3
Visualization
WinCC (Unified, Comfort, Advanced), visualization with templates, recipe management, user management, alarming, trends, diagnostics
- S4
Testing & Simulation
Functional testing at workshop, Simulation with PLCSIM Advanced, Hardware-in-the-Loop (HIL), Testing of All Scenarios
- S5
Drive Technology Integration
Variable Frequency Drives (VFD), Servo Axes, SINAMICS G120/S120 Integration via PROFIdrive, Positioning with Technology Objects
- S6
Process Control & Optimization
Optimize PID control loops, Fuzzy Logic for complex processes, Throughput optimization, Quality assurance (SPC)
- S7
On-Site Commissioning
Hardware installation, Network configuration, On-site functional testing, Troubleshooting and optimization, Documentation
- S8
Training & Acceptance
Operator and maintenance training, final on-site acceptance, Documentation handover, Service agreements
Technology Competence
Proven automation technology for industrial production facilities
PLC Programming
- Siemens TIA Portal (S7-1200/1500)
- STEP 7 Classic (S7-300/400)
- Programming languages: STL, LAD, FBD, SCL
Functional Safety
- ISO 13849 (Performance Level up to PL e)
- ProfiSafe Engineering
- Distributed Safety
- Safety functions: SS0, SS1, SS2, SLS, STO
- Safety validation & approval
HMI & Visualization
- WinCC Comfort / Advanced
- WinCC Unified
- HMI migration: WinCC Flexible / Comfort panels upgraded to Unified
- Recipe management & batch control
- Multilingual operator interfaces
- Alarm management & diagnostics
Drive Technology
- SEW (MOVIAXIS, MOVIDRIVE, MOVITRAC)
- SINAMICS (S120, G120, G120C)
- Danfoss VLT frequency drives
- Advanced bus positioning
- Axis coupling & motion sequences
Process Automation
- PID control (pressure, temperature, flow, level)
- Analog control & limit controllers
- Batch management & recipes
- Process optimization & fine-tuning
- Sequence controls
Sensors & Tracking
- Barcode scanners (1D/2D)
- 3D scanners & vision systems
- Safety light curtains
- FIFO tracking & data tracking
- Reflex sensors & object detection
- Initiators & limit switches
Interfaces & IT/OT Integration
- PROFINET / PROFIBUS / ProfiSafe
- AS-Interface (AS-i) and IO-Link: commissioning, fault finding and S7 integration via gateways or IO-Link masters in TIA Portal
- OPC UA
- Modbus TCP/IP
- Industrial Ethernet
- PN/PN & DP/DP couplers
- S7 communication
- WCS/WMS interfaces
Program Recovery
- Re-documentation from online snapshot + scanned E-Plan pages
- Reverse engineering of S5 and S7-Classic (S7-300/400)
- Symbol reconstruction: combining online snapshot + E-Plan
- Direct migration to TIA Portal from online snapshot + E-Plan
- AI-assisted code analysis and re-documentation
AI Workflows & AI Consulting
- AI-assisted PLC programming in TIA Portal V21 (usable Openness API from V21)
- WinCC Unified panels: AI-assisted grunt work, manual refinement
- TIA Openness: automated engineering workflows via API
- AI as a booster: grunt work, diagnostics, hard problems
- AI consulting for plant operators and integrators
References
Selected automation engagements across manufacturing and process industries.
12/2018 – 02/2019 · Tobacco manufacturing
Track & trace for cartoner
Germany (DACH): Siemens S7-315-2 DP, MicroHAWK ID-40 cameras and RS232 interfaces deliver end-to-end pouch and case tracking on the cartoner.
Impact
- Batches remain fully traceable – every pouch position is stored
- Quality deviations are rejected automatically and documented for audits
11/2022 – 07/2023 · Tobacco manufacturing
Foreign material control in PloomS line
Poland (EMEA): Siemens S7-1511F, TOMRA Helius sorter and string remover ensure foreign material detection with cross-line ProfiSafe communication.
Impact
- Foreign material and strings are detected and rejected reliably – product safety increases measurably
- Product quality stays stable, even with recipe changes and parallel line starts
04/2023 – 2024 · Tobacco manufacturing
AGV-supported hall transfer
Germany (DACH): ek robotics AGVs, Siemens S7-414F controls and WinCC link hall 8 and hall 2, including buffer conveyors, barcode validation and shuttle integration.
Impact
- Material flow between halls 8 and 2 is decoupled and transparent – no manual transports required
- Line supply stays stable during mixed operation, maintenance and shift changes
Frequently Asked Questions
Answers on retrofit, program recovery, AI consulting and commissioning in the Saar-Lor-Lux region
What are your core service areas?
Commissioning of new production lines and retrofit of existing systems – both equally weighted. Preferred region Luxembourg and Saar-Lor-Lux, available worldwide. Hourly or daily rates, fixed-price quote also possible.
Which retrofit migrations do you offer?
S5 and S7-300/400 to S7-1200 or S7-1500 (Failsafe variants included) with TIA Portal, plus HMI retrofit to WinCC Unified (from WinCC Flexible, WinCC Comfort/Advanced or older touch panels). Complete package: program conversion, hardware migration, commissioning and operator training – with minimal downtime.
Can you recover a PLC program when no symbols remain?
Yes. Typical case: only an online snapshot available, data blocks not documented, no network comments. The basis for reconstruction is online snapshot + scanned E-Plan pages. From these I reconstruct symbols and documentation, AI-accelerated. Works for S5 and S7-Classic (S7-300/400). On request directly combined with migration to TIA Portal.
How does HMI migration to WinCC Unified work?
WinCC Flexible (S7-300/400 world) and WinCC Comfort/Advanced (the old TIA WinCC) cannot be auto-migrated to Unified – all screens must be rebuilt. AI-assisted workflows take the grunt work (pre-generating screens), followed by manual refinement. Often combined in the same retrofit step with the PLC migration.
What specifically do you offer as AI consulting?
AI consulting for plant operators and integrators: AI-assisted PLC programming in TIA Portal V21 (usable Openness API from V21 onward), TIA Openness for automated engineering workflows, WinCC Unified panels pre-generated with AI, AI as a booster for grunt work, diagnostics and hard problems. Practical and in daily engineering use for nearly a year – no buzzword slideshow.
Which regions do you preferably work in?
Headquarters Luxembourg, residence Mettlach (Saarland). Preferred Saar-Lor-Lux region: Luxembourg, Saarland (Saarbrücken, Saarlouis, Merzig-Wadern), Rhineland-Palatinate (Trier, Saarburg, Bitburg). Short travel distances enable quick on-site appointments. Internationally available as well – over 30 international commissionings across 4 continents.
How do I start a request?
By phone (Luxembourg +352 26709351, Germany +49 176 34450924) – preferred, person to person. Alternatively by email to info@prybisch-automation.eu or via the contact form. Response within 24 hours on working days. Initial consultation free of charge. Hourly/daily rates or fixed-price quote depending on project scope.
Project planned or need support?
Free initial consultation – response time < 24h business days
✓ Non-binding consultation ✓ Response time < 24h ✓ International