We work in ethanol plants, foundries, and aggregate facilities—environments that demand high-capacity power systems, hazardous location expertise, and electrical infrastructure that holds up against the elements.
BY THE NUMBERS
Electrical systems in heavy industrial facilities have more than one responsibility. While it's imperative that they function properly for reliable operations, they also determine the safety of those working around it. These numbers reflect what well-engineered electrical and automation systems actually deliver.
Worker Injury Reduction
~15–25%
through automated handling and remote operations
Equipment Life Extension
~10–20%
with condition monitoring and predictive maintenance
Production Throughput Increase
~10–20%
with optimized conveyor and motor controls
Mining projects often spread electrical infrastructure across large sites. We understand that crusher plants, screening decks, conveyor systems, and wash plants run simultaneously, often miles from the nearest service infrastructure. Plus, dust and vibration degrade equipment faster than most environments and outdoor installations take weather impact year-round. PDC installs site power distribution, equipment wiring, and conveyor and crusher controls for aggregate operations. Given the scale of these sites, our team designs installations that are practical to maintain, clearly routed, and built to hold up in the field.
Site power distribution and service entrance installations
Crusher, screener, and processing equipment power wiring
Motor and process control wiring
Conveyor and material handling system controls
VFD controls for crushers, conveyors, and pumps
Lighting and lighting controls for plant and site areas
Redundant power systems and automatic transfer switches
Electrical troubleshooting and diagnostics
Low voltage systems: fire alarms, security, voice/data
Foundry electrical systems deal with loads and conditions that most industrial installations don't see—furnace systems drawing thousands of amps, extreme ambient heat, heavy particulate in the air, and casting and mold forming equipment that needs precise motor and process controls to produce consistent parts. PDC designs and installs power distribution, motor controls, and automation systems for foundry operations, including furnace and melt system power, conveyor and material handling controls, and OEM control system retrofits when aging equipment needs updated controls without full replacement.
Power distribution and wiring for furnace and melt systems
Motor and process control wiring for mold forming and casting equipment
Conveyor and material handling system controls
OEM control system retrofits and upgrades
Control panel fabrication (UL508A certified)
Lighting and lighting controls
Electrical troubleshooting and diagnostics
Thermal imaging and power quality analysis
Low voltage systems: fire alarm, security, voice/data
Ethanol production facilities are classified hazardous locations throughout grain receiving, fermentation, and distillation areas—flammable vapors are present, and every electrical installation in those zones has to meet NEC Class I requirements. PDC has installed electrical systems in ethanol plants across the region, handling hazardous location wiring, power distribution, motor controls, and process automation from grain handling through distillation. We understand which areas require explosion-proof equipment, where seal-offs are required, and how to work in classified environments without shutting down active production areas.
Power distribution and wiring for hazardous (Class I) locations
Motor and process control wiring
Conveyor and grain handling system controls
VFD and motor controls for pumps, blowers, and agitators
Process automation and PLC integration for fermentation and distillation
Hazardous location rated low voltage systems
CASE STUDIES
Electrical Contracting/Industrial
Brewster Cheese Plant and Summit Ridge Energy partnered to develop 22.66 acres of renewable energy across two adjacent solar arrays—a Distributed Generation (DG) field serving the cheese plant directly and a Community Solar field exporting to the ComEd utility grid.
ELECTRICAL & Automation/Heavy Industry
Badger State Ethanol recently completed a major expansion by doubling their dry-mill ethanol production to 80 million gallons.
Electrical Contracting/Heavy Industry
PDC delivered complete electrical installation for southwestern Wisconsin's first RNG facility, navigating classified-area complexities and repeated schedule surprises to finish on time, under budget, and six weeks ahead of the customer's projected production start.
Connect with PDC
Looking for comprehensive automation and electrical solutions that can jumpstart your business? Or are you searching for expert advice on the latest equipment? Contact our team today to discuss your needs, ask questions, and begin a trusted partnership that supports your long-term success.
