Thermal Oxidizer & RTO Controls
Our flagship specialty. We program, commission, and support the control systems that keep thermal oxidizers and RTOs running safely, efficiently, and in compliance. 250+ projects and counting.
What We Do for TO/RTO Systems
From initial programming through long-term support, we deliver controls engineering built around the unique demands of thermal oxidizer and RTO operation — combustion safety, valve sequencing, emissions compliance, and uptime. For background on how these systems operate, see our guides on how RTOs work and TO vs. RTO selection.
PLC Programming
Valve sequencing, heatup/cooldown automation, bed switching logic, fault management, and process interlocks — all built for reliable, repeatable operation.
BMS & Safety
NFPA 86 burner management system programming, safety relay integration, flame safeguard logic, purge sequencing, and safe shutdown design.
HMI & SCADA
Operator interfaces with real-time process graphics, alarm management, trend logging, remote monitoring dashboards, and mobile-ready views.
Commissioning
On-site startup, loop checkout, safety system verification, stack test support, and operator training to get your system running right the first time.
Troubleshooting
Emergency response, failed valve diagnostics, BMS lockout recovery, remote support, and root cause analysis to minimize downtime.
Compliance Systems
Title V data logging, CAM parameter monitoring, deviation tracking, and automated reporting to support environmental permit requirements.
Equipment We Support
We work across the full range of thermal oxidizer and air pollution control equipment used in manufacturing environments. Our experience spans every major OEM platform and custom-built systems.
Regenerative Thermal Oxidizers
2-bed, 3-bed, and rotary valve RTO configurations — including valve sequencing, bake-out cycles, and energy recovery optimization.
Direct-Fired Thermal Oxidizers
Single-chamber and multi-zone direct-fired systems with combustion temperature control and residence time management.
Catalytic Oxidizers
Recuperative and regenerative catalytic oxidizers with preheat control, catalyst bed monitoring, and performance trending.
Afterburner Systems
Simple afterburner controls with temperature regulation, safety interlocks, and burner management integration.
Associated Equipment
Scrubbers, quench towers, inlet/outlet damper systems, heat exchangers, and ductwork control that support the primary oxidizer.
Industries We Serve
Our TO/RTO controls expertise supports manufacturers across a wide range of sectors where VOC abatement and emissions compliance are critical:
PLC Platforms
We program all major PLC families and integrate with leading burner management controllers. Platform selection is driven by your plant standards and application requirements.
Allen-Bradley (Rockwell)
ControlLogix, CompactLogix, MicroLogix — Studio 5000, FactoryTalk, and Logix 5000 programming.
Siemens
S7-1500, S7-1200, TIA Portal — PROFINET and PROFIBUS networking for distributed I/O.
Honeywell BMS
RM7800, RM7840, RM7890 flame safeguard controllers — wiring, configuration, and integration with PLC logic.
Legacy & Multi-Vendor
PLC-5 and SLC-500 migrations, multi-vendor integration, and bridging legacy BMS controllers to modern platforms.
Related Services
Our TO/RTO controls work connects directly to these core service areas: