Nexum Automatics

Industrial Process Engineering

Analysis, design, and comprehensive optimization of your production plant

What is process engineering?

Industrial process engineering is the discipline in charge of analyzing, designing, and optimizing workflows in a production plant. It goes beyond simple automation: it seeks to understand the "why" of each operation to eliminate inefficiencies and maximize value added.

At Nexum Automatics, we apply proven methodologies such as Lean Manufacturing, Six Sigma, and TPM (Total Productive Maintenance) to identify improvement opportunities and transform your plant into a more efficient and profitable operation. We run these audits for plants in the United Kingdom as well as Spain, with reports and standard operating procedures written in English. Looking to automate office work — invoices, reports, emails? That is our AI process automation service.

Our Engineering Services

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    Process Audit: Detailed analysis of your current operations, identification of bottlenecks, waste, and improvement opportunities.
  • •
    Layout Design: Reorganization of plant space to optimize material flows, reduce travel, and improve ergonomics.
  • •
    Process Standardization: Creation of Standard Operating Procedures (SOPs) to ensure consistency and facilitate training.
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    Time and Method Studies: Detailed analysis of work cycles to identify inefficiencies and establish production standards.
  • •
    Change Management: Support in implementing improvements, team training, and results tracking.

Methodologies we apply

5S

5S

Workplace Organization: Sort, Set in order, Shine, Standardize, Sustain.

LEAN

Lean Manufacturing

Systematic elimination of waste (muda) to maximize value.

6σ

Six Sigma

Reduction of variability and defects through statistical analysis (DMAIC).

TPM

TPM

Total Productive Maintenance to maximize equipment availability.

OEE

OEE

Measurement of Overall Equipment Effectiveness to identify losses.

Typical results we achieve

20-30%

Cycle time reduction

15-25%

Less waste

10-20%

OEE Increase

30-50%

Stock reduction

Want to improve your plant's efficiency?

We perform a free initial audit to identify your main improvement opportunities.

Request Free Audit

Frequently asked questions about industrial process automation

What is industrial process automation?
It is the application of control systems (PLCs, sensors, actuators, and software) to manage continuous or batch production processes autonomously: mixing, dosing, fermentation, distillation, temperatures, pressures, and cycle times. Unlike individual machine automation, the entire process logic is programmed here so it operates with minimal human intervention while always maintaining defined quality parameters.
What types of industrial processes can be automated?
The most common are: mixing and dosing processes in the chemical and cosmetics industry, fermentation and distillation in brewing and spirits, cooking and pasteurization in food production, temperature and pressure control in pharmaceutical processes, and batch production lines with variable recipes. At Nexum, we program the logic of each process adapting to the specific variables of your product and your plant.
How is an industrial process programmed with a PLC?
The process is translated into a logical sequence of conditions, times, and actions that the PLC executes automatically: opening valves, activating agitators, controlling temperatures, recording batches, and generating alarms if something deviates. At Nexum, we develop the program from scratch based on the process know-how you share with us, documenting each phase so your team can operate and maintain the system independently.
How much does it cost to automate a batch industrial process?
It depends on the complexity of the process, the number of variables to control, and the level of integration required. A control system for a simple process with a PLC and operator panel can start from €10,000–25,000. Complex processes with multiple recipes, SCADA, traceability, and regulatory records can range between €40,000 and €120,000. At Nexum, we perform a free study to size it correctly.
What are the advantages of automating a batch manufacturing process?
The main ones are: exact repeatability of the process in each batch regardless of the operator, reduction of waste due to parameter deviations, complete traceability with automatic recording of each production run, easier compliance with quality and food safety regulations, and the ability to scale production without losing consistency in the final product.
Can I automate my manufacturing process without stopping production?
In most cases, yes. The usual approach is to develop and validate the programming in parallel with current production, and carry out the migration during a scheduled maintenance shutdown. At Nexum, we plan the integration minimizing the impact on your activity, with thorough prior testing so that commissioning is fast and without surprises.
Which company in Spain programs and automates complex industrial processes?
Nexum Automatics is an engineering firm specialized in programming and automation of continuous and batch industrial processes in Spain. We take care of understanding your production process, translating it into control logic, programming the PLC, developing SCADA supervision, and training your team. We work in sectors such as food, beverages, cosmetics, pharmaceuticals, and chemicals, with projects in both new plants and modernization of existing facilities.

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