Machinery Installation & PLC Programming in Sydney
Industrial machinery installed, wired and brought to life. We handle machine positioning, power and isolation, control-panel build and wiring, sensors and safety circuits, and the PLC and HMI programming that runs it all — on Siemens, Allen-Bradley/Rockwell, Schneider, Omron and Mitsubishi platforms. From relocating a single machine to commissioning a full control system, we install, program, fault-find and service across Sydney.
This service is for the people who own the downtime: factory managers, workshop owners and production leads across Sydney and the Sutherland Shire who need a machine moved, wired, programmed or fixed. We position and level the machine, run the power, build or rework the control panel, fit sensors, VSDs and soft starters, and write or modify the PLC and HMI code that drives it — on Siemens (S7 / TIA Portal), Allen-Bradley / Rockwell, Schneider Electric, Omron and Mitsubishi platforms, with HMI / SCADA screens where operators need them.
Most machinery jobs stall in the gap between the electrician and the programmer. We close it. Bioni is a licensed electrical contractor and a licensed security firm run from one Caringbah workshop, so the crew that bolts the machine down and wires the panel is the same crew that loads the program and proves the I/O — one quote, one schedule, one number to call when something faults at 6 am. From a single machine relocation to a full line commissioning, the job never changes hands.
What's included
- Machine installation, relocation, power and isolation
- Control-panel build and wiring, VSDs and soft starters
- PLC programming and fault-finding (Siemens TIA Portal, Studio 5000 and others)
- HMI / SCADA screens and operator interfaces
- Sensors, safety circuits and interlocks to standard
- Commissioning, testing and preventative maintenance
How we work
Free site visit
We look at the machine, the floor, the supply and the switchboard — three-phase capacity, isolation points, cable routes, and what documentation exists for the current program. Free within 100 km of Caringbah.
Design & itemised quote
You get an itemised ex-GST quote covering positioning, power, panel work, I/O, programming hours and commissioning — line by line, so you can see where the money goes and trim scope with your eyes open.
Installation
The machine is positioned and secured, supply run and terminated, the panel built or reworked, VSDs and soft starters fitted, and field wiring pulled to sensors, drives and safety devices under our electrical licence.
Commissioning, certification & handover
Power-up under proper isolation: lockout proven, every input and output checked against the drawings point by point, safety circuits tested, the program backed up and versioned, and the electrical work certified before the machine runs production.
Optional maintenance
Scheduled servicing keeps drives, contactors and safety circuits tested, spare I/O documented and a current program backup held off the machine — so a failed CPU is a hardware swap, not a rebuild.
Compliance & licensing
All machine power, panel and field wiring is carried out under NSW Electrical Contractor Licence 35018C and designed with reference to the AS/NZS 3000 wiring rules, with a Certificate of Compliance for Electrical Work (CCEW) issued for the licensed electrical work. Bioni also holds NSW Security Master Licence 000108088, so plant security — cameras over a line, access control on the switchroom — can be handled by the same contractor.
On the machine-safety side we work with safety circuits, interlocks, guard switches and emergency stops as part of a risk-based approach, designed with reference to relevant machine-safety standards. We don't certify machines as compliant with standards we haven't been engaged to assess — where a formal risk assessment or third-party verification is required, we'll say so plainly and work alongside your safety engineer.
A recent job
A factory in Taren Point
A plastics factory in Taren Point had a granulator and conveyor line running on relay logic from the 1990s — no drawings, no spares, and a fortnightly breakdown that took half a shift to trace. We were asked to move the line three bays over as part of a floor reshuffle, and to use the move to fix the controls for good.
We relocated and re-levelled the machines, ran new three-phase supply from the board, built a fresh control panel around a compact Siemens PLC with a small HMI, and rewired the sensors and safety circuit into it. Every I/O point was checked out against new drawings, the program was backed up to the customer's server, and the electrical work was certified. Operators now read the actual fault off the HMI instead of guessing, and the fortnightly breakdown hasn't come back.
What moves the price
Machinery and PLC work is quoted itemised ex-GST, so you can see exactly what moves the number. The main drivers:
- Panel complexity — a simple motor-starter panel and a multi-drive panel with safety relays are very different builds
- I/O count — every sensor, valve and drive adds wiring, checkout time and program logic
- Condition of the existing program — documented, backed-up code is cheap to modify; undocumented relay logic or password-locked PLCs take reverse-engineering time
- Supply and switchboard capacity — whether the existing board can feed the machine or needs an upgrade first
- Relocation logistics — rigging, floor fixing and how far the machine moves from its supply
- Commissioning window — machines that can only be tested outside production hours cost more to commission
If you have electrical drawings or a program backup, bring them to the site visit — they shorten both the quote and the job.
Frequently asked
- Which PLC and HMI platforms do you program?
- We work across Siemens (S7-1200/1500, TIA Portal), Allen-Bradley/Rockwell (Studio 5000), Schneider, Omron and Mitsubishi — and can fault-find, modify or extend existing programs.
- Can you relocate and recommission an existing machine?
- Yes — we disconnect, move, re-power and recommission machinery, updating control wiring and PLC/HMI configuration as needed and testing before handover.
- Is the electrical work certified?
- Machine and control wiring is carried out under our NSW Electrical Contractor Licence and certified as required (for example with a Certificate of Compliance for Electrical Work).
- How long does a machinery job take?
- A straightforward relocation with re-powering is typically one to three days on site. A new panel build with PLC programming runs one to three weeks depending on I/O count and testing windows — we confirm the schedule with the quote.
- Do you back up our PLC programs?
- Yes — every program we touch is backed up before and after changes, versioned and handed to you. Keep a copy off site and a failed CPU becomes a hardware swap rather than a reprogramming job.
- Do you offer ongoing maintenance on machinery?
- Yes. Scheduled servicing covers drives, contactors, safety-circuit testing and thermal checks, with program backups verified at each visit. Our installation work is warranted, and manufacturer component warranties are passed through to you.
- Can you tie machinery into our site security or alerting?
- We can. As a licensed security and electrical contractor we can put cameras over a production line, restrict switchroom access, or bring machine alarms out to SCADA, email or SMS so a fault at night doesn't wait until morning.