Heat Treatment & Furnace Control Systems
Expert temperature control and furnace automation for heat treatment processes
Precise temperature control is critical in heat treatment operations. Whether you're running carburising furnaces, hardening ovens, or tempering lines, controller failures and calibration issues directly impact product quality and energy costs. Industrial Control Services specialises in Eurotherm temperature control systems, ePower SCR power controllers, and chart recorder integration for Staffordshire's heat treatment industry.
Temperature Control Systems We Support
Eurotherm Controllers
- 2000 series (2404, 2408, 2416)
- 3000 series programmable controllers
- nanodac & piccolo recorders
- EPower & EPC3000 SCR power controllers
- iTools configuration software
Chart Recorders
- Eurotherm Chessell recorders
- Paperless data logging systems
- Temperature profile documentation for quality certification
- Historical data retrieval and analysis
Power Control
- ePower SCR thyristor controllers
- Single & three-phase power regulation
- Heating element protection and soft-start
- Power monitoring and energy measurement
Common Heat Treatment Control Problems
Temperature overshoot - Poor PID tuning causing product scrapping, wasted energy, and premature element failure
Controller failures - Display faults, relay failures, corrupted programs on critical furnace controllers with no backup
Chart recorder issues - Lost temperature records affecting quality certification, audit trails, and process validation
Energy waste - Inefficient control strategies, poorly tuned loops, and excessive idling consuming unnecessary power
Legacy system support - Obsolete Eurotherm controllers with no documentation, replacement parts increasingly difficult to source
Calibration drift - Thermocouples degrading, control accuracy deteriorating, leading to out-of-spec products
Our Heat Treatment Services
Emergency Controller Replacement
When a furnace controller fails, we carry common Eurotherm spares and can often get you running same-day. We upload existing programs where possible or recreate control strategies from your process specifications.
PID Tuning & Optimisation
Poorly tuned controllers waste energy and damage products. We optimise control loops for faster heat-up, accurate soak temperatures, and minimal overshoot - improving quality while reducing electricity consumption.
Chart Recorder Installation
Quality standards often require documented temperature profiles. We install and configure Eurotherm recorders with proper calibration certificates and integrate them with your existing controllers.
ePower Controller Programming
SCR power controllers need correct current limiting, soft-start settings, and alarm configuration. We programme ePower units for optimal heating element life and energy efficiency.
Energy Monitoring Integration
While working on your temperature controllers, we can add LoRa wireless monitoring to track actual furnace energy consumption, identify idle-time waste, and measure the impact of control improvements.
Typical Heat Treatment Projects
- Carburising furnace controller replacement and re-commissioning
- Hardening line profile recorder installation for automotive certification
- Tempering oven PID optimisation reducing cycle times by 15%
- Multi-zone furnace power controller programming
- Legacy Eurotherm 2000 series upgrades to current 3000 series
- Energy sub-metering on heat treatment departments
Why Heat Treatment Operators Choose Us
- Process knowledge - We understand carburising, hardening, tempering, annealing processes
- Fast response - Furnace downtime costs thousands per day, we prioritise urgent callouts
- Eurotherm specialists - Deep experience across 2000/3000 series and ePower platforms
- Quality compliance - Proper documentation for AMS2750, CQI-9, Nadcap requirements
- Energy savings - Better control = lower electricity costs and improved process efficiency
Real-World Example
A Staffordshire automotive heat treatment facility was experiencing 25°C temperature overshoot on their carburising furnace, causing extended cooling times and scrapped parts. After PID re-tuning and ePower soft-start optimisation, overshoot reduced to <5°C, cycle time decreased by 12 minutes, and electricity consumption dropped by 18% - saving over £8,000 annually while improving product quality.
Get Expert Support Today
Experiencing temperature control issues affecting product quality or energy costs? Contact Industrial Control Services for specialist Eurotherm and heat treatment control support.