ABOUT US

​​​Established in 2012

Align Automation is built on a strong international and New Zealand industrial history.

With a long and varied background in electromechanical engineering and electrical services.

 

Marine Engineering

 

Align Automation's control systems engineering foundation began with a seven-year apprenticeship within Vosper Thornycroft’s Controls Division, specialising in the design, manufacture, testing and commissioning of advanced naval control systems.

​

During this period, experience was gained developing and supporting Versatile Control Systems (VCS)—modular naval control and monitoring architectures designed for demanding shipboard applications. These systems were installed across major naval platforms, including Type 23 frigates and 56-metre patrol vessels.

​

A hands-on approach was applied across all aspects of electrical control system engineering, including control panel assembly, PCB manufacture and testing, quality control, control panel wiring, distributed power systems, onboard control system installation, cable interconnections, systems integration, commissioning, and technical support through harbour acceptance testing and sea trials.

​

This early exposure to highly engineered, mission-critical control systems established the foundation for practical automation engineering focused on reliability, maintainability and performance in demanding operational environments.

 

Explosive Atmospheres

​​

This was followed by three years within the pharmaceutical process control engineering working with Aeromatic-Fielder, a well established and highly regarded original equipment manufacturer of hazardous area pharmaceutical processing equipment . 

 

This was followed up with over six years working for the D H Morris Group on hazardous area pumping systems service work for BP. 

 

Prototype Wiring

​

Additional experience includes broader industrial maintenance and engineering support roles across multiple sectors including almost a year working for CRA (Contracting Research Agency) on prototype panels.

​

New Zealand 

 

As highlighted on our website, work in New Zealand has included service engineering, systems design, integration, maintenance, and commissioning support across a range of small to medium sized industrial automation and control system applications.

​

Our experience spans everything from supporting and upgrading existing equipment to designing and implementing new automation solutions. Whether integrating with legacy systems, OEM equipment, contractor-supplied installations, or developing entirely new systems, we focus on practical engineering, reliable outcomes, and long-term maintainability.

 

​From the beginning of 2019, the focus of work shifted  solely toward machine and plant services incorporating PLC control systems design and programming in conjunction with industrial automation and control system development.​

​

Built for Clarity in the Field

 

In automation projects, challenges often arise at the interface between system design and on-site interpretation. This is rarely a matter of capability or effort, but rather a difference in focus between disciplines.

​

Electricians and technicians typically prioritise speed of installation, familiar patterns, and clarity under time pressure. Control system designers, on the other hand, must consider longer-term factors such as system scalability, fault finding, safety interlocks, and future modification.

​

Because of this, even well-structured systems can sometimes appear more complex than they are in operation. The key to bridging this gap is not simplification of function, but clarity of design—through consistent structure, logical organisation, and clear documentation that supports commissioning and maintenance in the field.

 

​Precision Engineering to Field Deployment

 

At the heart of our capability is a "start-to-finish" approach to industrial automation. We don’t just provide a solution; we own the entire lifecycle of the control system, ensuring that what we design in the office performs flawlessly in the harshest real-world environments.

​

In-House Panel Building: The Foundation of Quality

 

Everything begins in our workshop. By building our control panels in-house, we maintain absolute control over the quality, layout, and wiring standards of the system.

​

• Precision Engineering: Every wire, terminal, and component is meticulously placed for accessibility and long-term durability.

• Quality Assurance: We perform rigorous pre-shipment testing to ensure that when a panel arrives on-site, it is ready for immediate integration.

​

Office-Based Programming: Architectural Intelligence

 

Before a single line of code interacts with a motor, we develop the logic, kinematics, and safety protocols in a controlled office environment.

• Advanced Logic Design: We specialise in the development of complex motion algorithms, PLC/PAC logic, and safety routines tailored to specific hardware requirements.

• System Simulation: We utilise digital tools to validate control strategies, minimising debugging time once we reach the field.

​

Field Commissioning & Harsh Environment Deployment

 

We recognise that the true test of an automation system is its performance on the factory floor or out in the field. We are as comfortable in a climate-controlled server room as we are deep inside an industrial site.

​

• Expert Commissioning: We lead the on-site startup, ensuring that the software/hardware handshaking is perfect and that the system meets its operational KPIs.

• Field Resilience: We are no strangers to the "real world" of industrial maintenance. Whether it is crawling under a machine in the mud, working through oil and water, or operating in extreme weather conditions, we provide the hands-on support necessary to get equipment running and keep it that way.

​

The Advantage Of Our Approach

 

By bridging the gap between the office-based programmer and the field-based technician, we eliminate the disconnect that often plagues automation projects. You aren't just getting code; you are getting a partnership that understands how that code interacts with the physical world—from the clean desk in the office to the wet, gritty, high-pressure environment of the machine floor.

​

Keep It Simple. Keep It Practical

 

We believe good engineering starts with understanding the limits of our knowledge as well as our expertise.

 

Our work is grounded in proven automation, control systems, and industrial engineering experience, while remaining open to research, development, prototyping, and technically challenging projects where the solution is not yet known.

 

We apply a disciplined, risk-aware approach to innovation, using investigation, testing, and iterative development to solve complex problems.

 

We undertake work within our proven competencies, recognise the boundaries of our expertise, and collaborate with suitably qualified specialists whenever a project requires additional knowledge, certification, or resources.

 

The result is practical, honest engineering focused on delivering the best outcome for every project.