Engineering services for production TwinCAT machine systems.
What we do
PLC and motion control
- TwinCAT 3 architecture, reusable libraries, and Beckhoff machine software delivery
- Reliable homing, restart, sequencing, and machine state handling
- Motion tuning for throughput, repeatability, and maintainability
HMI and operator workflows
- Operator-first screens with alarm-driven interaction and clear diagnostics
- Recipes, role-based behavior, and multilingual operating concepts
- Interfaces that fit production instead of demo-only prototypes
Data and system connectivity
- OPC UA, MQTT, SQL, REST, and edge services around the machine
- Factory data flows for batch records, traceability, and reporting
- Python services for MES handshakes, job dispatch, and diagnostics
Validation-aware delivery
- Structured change control for regulated and high-downtime environments
- Clear documentation for machine changes, tests, and release scope
- Engineering decisions made with production risk in mind
Engineering tooling
- Python utilities for commissioning, testing, and service workflows
- Reusable TwinCAT helpers instead of one-off scripts per machine
- Practical automation for internal teams, suppliers, and customer sites
Lifecycle support
- Remote diagnosis, on-site interventions, and upgrade planning
- Migration support for machines that need to keep shipping
- Training and handover for operators and engineering teams
Digital Twin and simulation
- Simulation-based PLC programming before the physical machine is ready
- Repeatable tests for sequences, interlocks, faults, and recovery
- Virtual commissioning to reduce rework and support on-time delivery
Simulation-based programming for software that works on time.
Test your machine software before the machine is ready. We use digital twins to develop and test PLC logic against a simulation of the machine, so your team can resolve issues earlier and make every engineering iteration count.
From normal production cycles to sensor faults and restart sequences, simulation makes machine behavior repeatable and testable. The result: more effective development, fewer bugs at startup, and a clearer path to on-time delivery.
Discuss your Digital TwinFrom simulation to production
- 1
Model the machine
Represent sensors, actuators, motion, and process behavior in a digital twin connected to the PLC software.
- 2
Program, simulate, improve
Exercise operating sequences, inject faults, and test recovery. Find logic errors early and repeat the checks as the software evolves.
- 3
Commission with confidence
Bring tested logic to the physical machine, verify it against real behavior, and focus on tuning and final acceptance.
See our digital twins in action.
Two examples of how we prepare machine software, examine complex sequences and find issues before commissioning.
Freeze-dryer loading & unloading
Frame loading, conveyors, shelf transfers and vial outfeed, brought together in one digital twin. See how we make machine interactions visible and prepare coordinated software sequences before physical commissioning.
Transcript & simulation scope
At Agile Automation, we get the job done. We bring hands-on automation experience and modern software engineering to demanding projects, with a clear focus on quality, cost and the result your business needs. We take ownership, solve the difficult problems, and choose practical approaches that make the most of your budget. Through careful integration, simulation and testing, we find issues early and keep your project moving towards production. And our commitment continues after handover. We have your back, helping your team keep the line running reliably and meet production targets. When challenges arise, we work with you to resolve them. As your needs change, we support upgrades and improvements that help your production move forward. Agile Automation. Engineering that delivers. Support that lasts.
In this film: Installation overview, frame loading and conveyor feed, freeze-dryer loading and shelf indexing, unloading, turntable and vial outfeed.
Recorded offline simulation using provisional mechanics, including unloading and empty-ring removal interfaces. This demonstration does not establish validated PLC operation or approval of a proposed machine modification.
Vial filling & pre-seal handling
Six-needle filling, pre-seal placement and product routing, including the rejection of a vial with a high pre-seal. See how simulation helps us examine process sequences and inspection decisions, so issues can be found earlier in software development.
Transcript & simulation scope
Machine software should be ready before the pressure of commissioning begins. At Agile Automation, we use digital twins to develop and test PLC programs while the machine is still taking shape. We check sequences, interlocks and recovery in a controlled environment, so problems can be found early and engineering time is spent where it matters. Our approach brings practical automation experience together with modern software tools, with a clear focus on quality, cost and getting the job done. And delivery is only the beginning. We support your team in meeting production targets, resolving challenges and making improvements as your line evolves. From the first simulation to the next upgrade, we have your back. Agile Automation. Engineering that delivers. Support that lasts.
In this film: Installation and inlet transfer, filling and dosing, pre-seal placement, straight-track to segment handover, and the high-pre-seal vial's route through the reject wheel and chute.
Recorded offline simulation with an existing high-pre-seal fault demonstration. Mechanical assumptions and control behavior require project-specific technical validation; this film does not establish validated production operation.
Concept simulations — subject to technical validation and customer approval.
More effective engineering
Develop and test while the machine is still being built. Shorten feedback loops and spend less time waiting for hardware.
Fewer bugs at startup
Check edge cases, interlocks, and restart behavior in repeatable simulations before they become commissioning surprises.
Software ready on time
Reduce late rework and commissioning pressure, helping your team deliver reliable machine software on schedule.
Deep expertise
Other PLC platforms we support
Schneider Electric / Machine Expert
We support Schneider platforms when the machine architecture or installed base requires it, with the same focus on maintainability and production-ready motion behavior.
- Deep knowledge of Schneider machine templates and structured application architecture
- Programming for machines with many synchronized axes, coordinated motion, and demanding sequencing
- Commissioning support for diagnostics, recipes, alarms, changeovers, and machine recovery behavior
Siemens / TIA Portal
For Siemens environments, we cover the PLC, safety, motion, and HMI stack with engineering that is readable, testable, and practical to hand over.
- Expert-level SCL development for reusable machine modules and clear state-oriented control logic
- Failsafe engineering, motion control, and coordinated axis applications in TIA Portal
- WinCC screens, alarms, diagnostics, recipes, and operator workflows aligned with production use
Agile Automation Technologies GmbH is a member of the EtherCAT Technology Group.
ETG membership supports our Beckhoff and EtherCAT-focused engineering work across machine software, integration tooling, and production-ready delivery.
Need focused support on a machine or platform rollout?
Tell us what you are building, where the current blocker is, and what the target architecture should support.