The Premier Control Integrators in North Carolina.
Transform your manufacturing operations with precision control systems designed for maximum efficiency and reliability. Carolina Controls NC LLC delivers comprehensive automation solutions that keep North Carolina's industries running at peak performance.
Specialized Plastic Extrusion & Manufacturing Support
Whether you're running blown film lines, pipe extrusion equipment, or complex profile manufacturing systems, our certified technicians understand the unique challenges of your industry. We don't just fix problems – we engineer solutions that prevent them.
Complete Control System Solutions
Custom Control Panel Design & Fabrication
Engineer precision-built control panels that withstand the demanding conditions of industrial manufacturing. Every panel is designed with your specific operational requirements, safety standards, and future expansion needs in mind.
Advanced PLC Programming
Develop robust programmable logic controller systems that automate your processes with precision and reliability. Our PLC solutions integrate seamlessly with existing equipment while providing the flexibility to adapt as your business grows.
Intuitive HMI Development
Create user-friendly human-machine interfaces that put critical process data at your operators' fingertips. Reduce training time and human error with displays designed for clarity and ease of use.
VFD & Servo System Integration
Optimize energy efficiency and process control with variable frequency drives and precision servo systems. Cut energy costs by up to 40% while improving product quality and consistency.
Legacy System Modernization
Breathe new life into aging equipment with modern control technology. We specialize in upgrading obsolete systems without disrupting your production schedule or requiring complete equipment replacement.
Emergency Troubleshooting & Repair
When production stops, every minute costs money. Our rapid-response team provides 24/7 emergency support to diagnose problems quickly and implement lasting solutions that prevent future failures.
Why North Carolina Manufacturers Choose Carolina Controls
Proven Track Record
Our clients consistently achieve 25-35% productivity improvements with reduced maintenance costs and extended equipment life. We measure success by your success.
Local Expertise, Statewide Coverage
Based in North Carolina with deep roots in the local manufacturing community. We understand the unique challenges facing Tar Heel State industries and respond quickly when you need us most.
Future-Ready Technology
Stay ahead of Industry 4.0 trends with IoT-enabled monitoring systems, predictive maintenance capabilities, and cloud-based data analytics that give you unprecedented insight into your operations.
Certified & Insured Professionals
Licensed technicians with decades of combined experience in industrial automation. Fully insured for your peace of mind and protection.
Industries We Serve
Plastic Manufacturing
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Blown film extrusion
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Pipe and conduit manufacturing
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Profile and window manufacturing
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Sheet and thermoforming operations
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Recycling and reprocessing equipment
General Manufacturing
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Food and beverage processing
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Textile and fiber production
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Chemical and pharmaceutical
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Automotive components
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Packaging and converting
Get Started Today
Ready to optimize your manufacturing operations? Our expert team provides complimentary facility assessments and detailed improvement recommendations at no cost to you.
Free Services Assessment
Our certified technicians will evaluate your current systems, identify improvement opportunities, and provide a detailed roadmap for enhancing efficiency and reliability.
Custom Solution Development
Every operation is unique. We design automation solutions specifically tailored to your processes, budget, and long-term business objectives.
Ongoing Partnership
From initial installation through ongoing maintenance and future upgrades, Carolina Controls NC LLC is your trusted partner for all industrial automation needs.
Our Services
Onsite Support
We’re ready to support you—onsite and on demand. Whether you're facing PLC or HMI issues, or troubleshooting AC/DC motors and drives, we bring hands-on expertise directly to your facility. Fast diagnostics, practical solutions, and minimal disruption—that’s our promise.
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SCADA
From intuitive dashboards to full-scale SCADA systems, we deliver tailored visualization solutions that fit your operation and budget. With hands-on experience in Ignition, FactoryTalk View SE, and Optix, we build interfaces that empower operators, streamline decision-making, and drive performance.
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Controls Retrofits
Need to upgrade an aging PLC but don’t want to overhaul your entire control panel? We specialize in seamless PLC replacements that preserve your existing infrastructure—saving you time, cost, and downtime.
Electrical Schematics
Need to update your electrical drawings or start fresh? We’ve got you covered. Whether it’s revising existing schematics or recreating complete electrical documentation from scratch, we deliver clean, accurate, and code-compliant drawings tailored to your system.
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Control Panel Builds
We design and build custom control panels that meet UL508A standards, ensuring safety, reliability, and code compliance. Whether you have preferred brands or want our trusted recommendations, we’ve got you covered. We specialize in Allen-Bradley and Siemens, but we’re happy to work with your specs to deliver exactly what your operation needs.
PLC/HMI Program Conversion
Upgrading your PLCs or HMIs but switching brands or software platforms? No problem. We specialize in cross-platform migrations—whether you're moving from Siemens to Allen-Bradley, Click to CODESYS, or anything in between. We handle the programming, conversion, and commissioning so you don’t have to worry about compatibility headaches.
Why Choose Us?
Tailored Engineering Solutions
At Carolina Controls NC LLC, we bring deep experience with leading industrial automation platforms including Allen-Bradley, Siemens, Omron, Automation Direct, Ignition, Codesys, and more. Our team doesn’t just design control systems—we engineer custom automation solutions that align with your production goals, operational requirements, and long-term vision.
Whether you're performing a legacy controls upgrade, launching a new PLC/HMI system, or integrating SCADA and data collection tools, we tailor every detail to deliver performance, reliability, and scalability. From control panel design to cross-platform migrations, we help manufacturers across the Southeast streamline operations, reduce downtime, and future-proof their automation infrastructure.
Expertise in Extrusion and Plastic Manufacturing
With over 15 years of hands-on experience in industrial automation and extrusion control systems, Carolina Controls NC LLC helps manufacturers across the Southeast maximize extruder performance, optimize process efficiency, and boost system reliability. Our deep understanding of single screw extrusion dynamics allows us to deliver custom automation solutions that reduce downtime, improve throughput, and enhance overall quality control.
✅ Our Proven Enhancements Include:
• Increased extruder output through advanced process optimization techniques
• Improved heater control for consistent temperature regulation and energy efficiency
• Enhanced system reliability to minimize unscheduled maintenance and production delays
• Significant energy savings through DC-to-AC motor conversions.
Whether you're upgrading legacy equipment or launching a new extrusion line, Carolina Controls NC LLC delivers precision-engineered solutions through PLC/HMI programming, SCADA integration, UL508A panel design, and cross-platform migrations—all backed by responsive onsite and remote support.
🚨 Fast, Reliable Automation Support Across the Southeast
Carolina Controls NC LLC, based near Hickory, North Carolina, provides rapid onsite and remote automation support to manufacturers throughout the Southeast US, including the greater Charlotte region. Whether you're facing an urgent equipment issue or planning routine controls maintenance, our team is ready to travel on short notice to keep your systems running at peak performance.
From emergency PLC troubleshooting and SCADA diagnostics to scheduled service calls and control panel upgrades, we specialize in minimizing downtime and maximizing efficiency. Our expertise spans leading platforms like Allen-Bradley, Siemens, Omron, and Automation Direct, ensuring you get responsive, knowledgeable support when and where you need it.
Our Impact in Numbers
100+
Projects Completed
50+
Satisfied Clients
98%
Client Satisfaction Rate
10+
Industry Recognitions
25+
Years of Experience
Trusted Partnerships
Client Testimonials
John Smith
CEO, Manufacturing Co.
Working with Carolina Controls NC Rev2 has been instrumental in optimizing our production processes. Their engineering solutions are top-notch and have truly transformed our operations.
Emily Johnson
CFO, Polymer Innovations
Carolina Controls NC Rev2 provided us with exceptional consulting services. Their team's expertise and dedication are unmatched, and we highly recommend their services.
Michael Brown
CTO, Plastic Solutions Ltd.
We are impressed with Carolina Controls NC Rev2's continuous support and commitment to our success. Their proactive approach to engineering challenges sets them apart in the industry.