How much does industrial automation cost in India?

Industrial automation costs ₹20 lakhs-₹20+ crores based on scope. Small line automation costs ₹20-50 lakhs, medium factory automation ₹50 lakhs-₹2 crores, large facilities ₹2-10 crores. Consulting fees are 5-12% of project cost. Typical payback period is 1.5-4 years through labor savings, productivity gains, and quality improvements.

What's the difference between PLC and SCADA systems?

PLC (Programmable Logic Controller) is hardware controlling individual machines/processes through programmed logic. SCADA (Supervisory Control And Data Acquisition) is software providing centralized monitoring and control of multiple PLCs across facilities. PLC handles real-time control; SCADA provides visualization, data logging, and remote operation. Most automation projects use both together.

How long does industrial automation implementation take?

Complete industrial automation implementation takes 4-6 months including feasibility study (2-4 weeks), detailed design (4-6 weeks), procurement (2-3 weeks), programming (3-4 weeks), installation (4-6 weeks), commissioning (2-4 weeks), and training (1-2 weeks). Complex projects may require 8-12 months. SARK provides detailed project timelines upfront.

What ROI can I expect from industrial automation?

Typical industrial automation ROI includes 30-60% productivity increase, 40-70% labor cost reduction, 50-80% quality improvement, and 20-40% energy savings. Payback periods range 1.5-4 years depending on project scope. For ₹1 crore investment, expect ₹40-60 lakhs annual savings. SARK provides detailed ROI analysis before project commitment.

Do I need to shut down production during automation implementation?

Most automation projects are implemented during planned shutdowns or phased to minimize production disruption. Small projects may require 1-2 weekend shutdowns. Medium projects need 1-2 week planned outage. Large retrofits are phased over 3-6 months with minimal disruption. SARK specializes in brownfield automation with minimal downtime strategies.

Expert Industrial Automation Consulting Services in India | SARK Engineers

Are you looking for professional industrial automation consulting to boost productivity by 30-60% and reduce operational costs? SARK Engineers & Consultants offers comprehensive industrial automation solutions across India, helping manufacturing industries transform their operations through smart factory implementation, PLC/SCADA systems, robotic automation, and Industry 4.0 technologies.

As experienced industrial automation consultants, we specialize in designing, implementing, and optimizing automation systems for manufacturing plants, process industries, and production facilities. Our expert team provides end-to-end solutions from feasibility studies to system integration, ensuring seamless digital transformation and measurable ROI.

Need to hire automation consultant for your facility? Contact SARK Engineers today at +91-9258087903 or email techno@sarkengg.in for a customized industrial automation consulting quote and start your journey toward smart manufacturing!

What is Industrial Automation Consulting?

Industrial automation consulting provides expert guidance in evaluating, designing, and implementing automation technologies to optimize manufacturing processes, reduce labor costs, improve product quality, and enhance operational efficiency. Consultants assess your current operations, identify automation opportunities, recommend suitable technologies (PLC, SCADA, robotics, IIoT), and manage implementation for maximum ROI.

Key Components of Industrial Automation Consulting

1

Process Assessment & Feasibility Study

Current state analysis of manufacturing processes
Identification of automation opportunities
Cost-benefit analysis and ROI projection
Technology suitability evaluation
Risk assessment and mitigation strategies
Phased implementation roadmap

2

Automation System Design

PLC (Programmable Logic Controller) programming
SCADA (Supervisory Control and Data Acquisition) design
HMI (Human Machine Interface) development
Control panel design and wiring diagrams
Network architecture and communication protocols
Safety system integration (SIL certification)

3

Technology Selection

PLC brands: Siemens, Allen Bradley, Schneider, Mitsubishi
Industrial robots: ABB, KUKA, Fanuc, Yaskawa
Sensors and instrumentation selection
Variable Frequency Drives (VFD) specification
Industrial IoT platform selection
MES/ERP system integration

4

Implementation & Integration

Hardware installation and commissioning
Software programming and configuration
System testing and validation
Legacy system integration
Operator training programs
Documentation and manuals

5

Industry 4.0 & IIoT Solutions

Smart factory implementation
Predictive maintenance systems
Real-time production monitoring
Data analytics and dashboards
Cloud connectivity and remote access
AI/ML integration for process optimization

6

Data Analytics & Continuous Improvement

Real-time data acquisition from IIoT sensors, PLCs, and SCADA.
Advanced analytics and AI/ML tools for predictive maintenance.
Customizable performance dashboards and KPI monitoring.
Feedback loops and reporting for continuous process optimization.
Cloud-based analytics and digital platforms for remote monitoring.

Our Offerings

Industrial Automation Products

Industrial Automation Consulting

Industries We Serve

Manufacturing Sectors

Automotive OEMs and Tier 1/2/3 suppliers
Electronics and semiconductor fabrication
Pharmaceutical tablet/injection manufacturing
Food processing and packaging
Textile spinning, weaving, processing
Chemical and petrochemical
Metal forming and machining
Plastics injection molding and extrusion

Process Industries

Oil and gas refineries
Power generation plants
Water and wastewater treatment
Pulp and paper mills
Cement manufacturing
Mining and mineral processing

Emerging Industries like solar panel and EV

Emerging Sectors

EV battery manufacturing
Solar panel production
3D printing/additive manufacturing
Biotechnology and life sciences

Frequently asked questions

Industrial Automation

Water Audits

Industrial Automation Consulting

Environmental Impact Assessment

Energy Audits

Industrial automation consulting provides expert guidance in implementing automation technologies to optimize manufacturing. It's important because consultants bring specialized expertise in PLC, SCADA, robotics, and Industry 4.0, ensuring optimal technology selection, proper system design, and successful implementation. This expertise delivers 30-60% productivity gains with minimized risk and faster ROI.

Select automation consultants based on: relevant industry experience (5-10+ years), technical certifications (Siemens, Rockwell, Schneider), completed project portfolio with verifiable references, in-house programming and engineering team, post-implementation support capability, technology-agnostic approach, and transparent pricing. SARK offers all these with 20+ years experience and 200+ successful projects.