From push buttons to process intelligence: How ESMA uses HMIs from Beijer Electronics to simplify passivation automation
Simplifying process control for medical device, aerospace, and defense applications
Since 1972, ESMA has designed and manufactured ultrasonic cleaning and passivation systems for customers across the medical device, aerospace, and defense industries. Their equipment supports ultrasonic cleaning and passivation processes that remove free iron from stainless steel components and restore a corrosion-resistant surface for demanding medical and aerospace applications.
Today, more than 400 ESMA systems are installed worldwide, supporting customers ranging from small mom-and-pop shops to large manufacturers. In industries where process consistency, operator safety, and documentation are critical, ESMA continues to evolve its equipment to meet increasingly demanding customer requirements.
Moving beyond push buttons and switches
For many years, ESMA's equipment relied on traditional push buttons and selector switches for machine control. While effective, these hardwired interfaces limited flexibility and made it difficult to modify process parameters or introduce new functionality without hardware changes.
To provide greater flexibility, ESMA began looking for a more modern operator interface.
"Our controls were pretty rigid with buttons and switches," explained one engineer. "Adding the HMI opened up a huge world of opportunity that we never had before."
Working with long-time controls partner Kiser Controls, which has recently become part of Impact Automation, ESMA upgraded its PLC platform and adopted Beijer Electronics X2 base 7-inch v2 HMIs. The touchscreen interface provided the flexibility to modernize its equipment while providing an interface that was easy for operators to learn and use.
Creating smarter, more flexible process control
Replacing physical controls with a touchscreen interface enabled ESMA to significantly expand the capabilities of its equipment.
Instead of relying on fixed machine settings, operators can now create and save custom process recipes, adjust cycle parameters through an intuitive interface, and access operating instructions directly from the HMI. ESMA has even incorporated videos and digital documentation to guide operators during machine operation, maintenance, and setup.
Making updates is equally straightforward. Using iX Developer, ESMA can modify HMI projects, email the updated files to customers, and have changes installed using a USB drive, eliminating the need for many onsite service calls.
This flexibility allows ESMA to continue adding functionality and making project updates without redesigning the operator interface.
Delivering process traceability for regulated industries
For many of ESMA's customers, successful cleaning is only part of the process. Medical device manufacturers and aerospace suppliers must also document every cleaning cycle to satisfy internal quality systems and industry certifications.
The Beijer Electronics HMI provides integrated data recording that allows customers to capture, retrieve, and archive process information for every completed cycle.
This information supports customer requirements like:
- Internal process validation
- FDA logging
- NADCAP audits certification documentation
by providing a complete record of each processing cycle.
Supporting a more automated cleaning process
Unlike conventional cleaning systems, where operators manually transfer parts from tank to tank, ESMA's equipment keeps the parts stationary while automatically moving the process fluids. This enclosed process improves operator safety by reducing exposure to dangerous chemicals and fumes.
The modular design provides additional flexibility by allowing the processing unit to be located separately from the holding tanks. This reduces the equipment footprint in cleanroom environments while giving customers more freedom when designing their facility layouts.
Once the parts are loaded, operators start the cycle and let the process run automatically. The result is a more streamlined workflow that eliminates the need for an operator to follow the parts through each stage of cleaning.
As ESMA describes the experience:
"Set it and forget it."
Designed for ease of use
Ease of operation has remained one of the greatest advantages of the Beijer Electronics platform.
With an intuitive touchscreen interface and minimal learning curve, operators quickly become comfortable using the equipment regardless of experience level. The straightforward interface simplifies installation, setup, and daily operation while reducing training requirements for new users.
From an engineering perspective, the HMI has been easy to maintain over the years. Its flexible software architecture allows ESMA to make updates and enhancements without extensive redevelopment, helping the company continue evolving its equipment as customer needs change.
Why ESMA continues to standardize on Beijer Electronics
Over the 15 years ESMA has partnered with Beijer, some customers have requested alternative HMI platforms. While ESMA initially accommodated those requests, the added complexity and maintenance challenges ultimately reinforced the value of the Beijer platform. Today, ESMA has standardized on Beijer Electronics and no longer accepts requests for alternative HMI vendors.
"Beijer Electronics has very few negatives, to be quite frank."
Driving the future of passivation
Today, with more than 400 systems installed across North America, Europe, Asia, Ireland, and South America, ESMA continues to provide automated cleaning and passivation systems that simplify operation, support process traceability, and help customers meet demanding industry requirements. As it expands further into aerospace, defense, and government applications, it continues to rely on Beijer Electronics as its standard HMI platform.
