PLC Programming
- •Siemens TIA Portal (S7-1200/1500)
- •STEP 7 Classic (S7-300/400)
- •Programming languages: STL, LAD, FBD, SCL
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.
From Planning to Commissioning
8 Steps for Successful Project Execution
Technology Competence
Proven automation technology for industrial production facilities
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
- •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
Get in touch✓ Non-binding consultation ✓ Response time < 24h ✓ International