Emerging Technologies: Modernizing Heat Treat Controls

Heat Treat Today’s contributing experts series on emerging technologies examines how modern automation and manufacturing tools are reshaping heat treat operations. In this Emerging Technologies installment, Alex Marcy, CEO of Corso Systems, discusses why programmable logic controllers (PLCs) and human machine interfaces (HMIs) must be current, sercure, and performing as designed before heat treaters add layers like analytics, data collection, or advanced integration. Marcy outlines what that readiness looks like, from updated firmware and cybersecurity alignment to reliable long-term operation, and explains how the benefits include reduced downtime risk, greater repeatability, and better data quality.

This informative piece was first released in Heat Treat Today’s September 2026 People of Heat Treat print edition.

Editor’s Note: Alex Marcy’s contributing columns to this series will cover his ten steps of progressive heat treat automation adoption. This column is just step one but yields fully actualized benefits even if you stop here. Look out for his future installments.

Programmable Logic Controllers (PLCs) and Human Machine Interfaces (HMIs) are the foundation of every automation system. PLCs run your equipment using logic to perform repeatable operations and HMIs give your staff control over and display the status of your equipment and production lines. Outdated, unsupported, or misconfigured PLCs and HMIs limit visibility, increase risk, and create roadblocks for future growth.

Ensuring these core systems are up to date is critical before adding technology layers like analytics, data collection, or advanced control and integration.

The first step towards a fully integrated manufacturing process focuses on validating that your control systems are current, secure, and performing as designed. This includes:

Ensuring up-to-date and functional process control logic for automated equipment
Updating firmware and software to supported versions
Aligning your system with current cybersecurity best practices
Verifying proper configuration and operation of your equipment, PLCs, and HMIs
Ensuring reliability and maintainability for long-term, repeatable operation of your system

Benefits of using PLCs and HMIs for heat treat operations include:

Reduced risk of downtime or system failure
Increased repeatability across production runs
Improved data quality and visibility

Taking the time to address PLC and HMI readiness now prevents costly delays later. If you are using relay logic or manual controls to operate your equipment, upgrading to a PLC and HMI is a great first step. Outdated PLC equipment puts you at risk of downtime if the hardware fails and should be considered for replacement every 10 years.

Using PLCs and HMIs to run your equipment sets you up for larger benefits gained from using manufacturing technology across your business.