About

A leading aluminum mill sought to modernize the electrical and automation infrastructure supporting its core environmental systems.The mill’s fume exhaust and treatment pumps systems are critical to maintaining air quality and regulatory compliance. The customer needed a reliable, efficient, and easily maintainable power and control solution to keep operations running smoothly with minimal downtime.

The Problem

Traditional on-site construction and wiring of control systems can be costly, time-consuming, and cause coordination challenges among multiple vendors. The customer needed a system that could be installed quickly, meet all state and local building codes, and provide long-term protection for sensitive electrical equipment from harsh industrial conditions.

The Solution

To meet the customer requirements, Premier Automation engineered and delivered a prepackaged Power Control Room (PCR), also known as an eHouse, as a complete turnkey solution.

The self-contained, modular enclosure was fully assembled, wired, and tested prior to shipment. Within the PCR, all cabinets and variable frequency drives (VFDs) were pre-mounted and interconnected, creating a ready-to-operate unit, cutting installation time in half.

Designed and integrated by Premier Automation’s in-house engineering team, the PCR provides:

• Code-Compliant Construction: The enclosure was built to meet or exceed state and local modular building specifications.
• Clean, Controlled Environment: The PCR acts as a clean room, protecting sensitive power equipment from dust, heat, and contaminants common in mill environments.
• Integrated Functionality: The eHouse powers and controls one of the plant’s main fume exhaust systems and treatment pumps, providing centralized, reliable operation of critical systems.
• Single-Source Accountability: Fully engineered, built, and tested by Premier Automation — one partner from concept to completion.
• Cost-Effective Implementation: Eliminated the need for complex multi-vendor coordination; only required final field wiring to the facility.

The Results

By leveraging Premier Automation’s engineering expertise and pre-engineered Power Control Room design, the aluminum mill achieved a future-ready, efficient, and low-risk installation. The plug-and-play design minimized production downtime and eliminated the need for extensive on-site integration work.

The result was a clean, code-compliant, and reliable control solution that enhances operational efficiency and long-term maintainability by protecting the mill’s critical automation infrastructure. This project exemplifies Premier Automation’s ability to deliver turnkey solutions that reduce risk, lower costs, and power industrial automation from concept to completion.