Accelerated Innovation Enabling the Future of Intelligent, Sustainable, Resilient, and Connected Industrial Systems Engineering
Industrial automation is entering a new era—one defined by intelligence, connectivity, and collaboration. It is no longer just about factory control; it is about building smart, software-defined systems where sensors, machines, and cloud platforms seamlessly interact to deliver agility, performance, and actionable insights. As AI in industrial automation, IoT, edge computing, and advanced control technologies converge, industrial ecosystems are being reimagined—transforming how products are engineered, how systems operate and learn, and how automation scales securely.
ACL Digital partners with industry-leading OEMs, IEMs, System Integrators, and Software Innovators to drive this transformation. We design and engineer a broad spectrum of intelligent industrial automation systems—from smart sensors, modular I/O systems, and multi-protocol controllers and gateways to user-centric HMIs and intelligent edge devices built with higher computing power and speed. By bringing deeper analytics closer to the machine, we embed safety, reliability, and cybersecurity into every layer. Our end-to-end systems engineering services combine hardware, mechanical, firmware, embedded software, digital engineering, and comprehensive system testing to help partners accelerate innovation, improve reliability, and drive intelligent industrial transformation—from sensor to cloud.
Our customer-centric engineering model accelerates innovation, shortens time-to-market, and ensures lifecycle reliability and compliance. With deep domain expertise and proven execution across automation technologies, ACL Digital empowers its partners to deliver differentiated products and platforms that are shaping the future of smart manufacturing and connected industries.
End-to-End System Engineering Service Excellence for the Future of Industrial Automation
Redesign and New Product Introduction (NPI)
Re-engineer or modernize existing systems while accelerating product realization through concept design, rapid prototyping, validation, and pre-compliance testing, ensuring faster time-to-market and industrial-grade reliability.
Smart Sensors & Intelligent Systems Engineering
Design and develop smart sensors, modular I/O systems, controllers, and gateways with embedded intelligence, AI-driven diagnostics, and edge connectivity for next-generation automation.
Industrial Connectivity & IIoT Solutions
Enable seamless integration and interoperability through multi-protocol integration including HART, EtherNet/IP, PROFINET, EtherCAT, OPC UA, Modbus, MQTT, and IO-Link—and engineer next-gen, secure, and scalable edge-to-cloud communication frameworks for connected, industry-wide operations and workflows.
Industrial Cloud & Edge Platform Enablement
Design and deploy cloud-native and hybrid edge-cloud architectures to enable seamless device onboarding, remote monitoring, and AI-driven analytics across major cloud ecosystems (AWS, Azure, GCP) and on-prem OT cloud environment.
Safety & Functional Compliance Solutions
Integrate SIL2/SIL3 safety frameworks (IEC 61508, IEC 61511) and develop intrinsically safe designs (ATEX) to ensure operational safety, system reliability, and global compliance.
Cybersecurity & Secure Architecture Solutions
Build secure-by-design architectures aligned with IEC 62443, including vulnerability assessments, VAPT, threat modelling, and secure firmware/software lifecycle management.
AI/ML & Analytics-Driven Solutions
Implement edge and cloud-based AI models for predictive maintenance, anomaly detection, and optimization. Transform industrial data into actionable intelligence with DataOps and ML-driven insights.
Manufacturing Process Automation & MES Integration Support
Enable industrial automation companies to digitally connect product and process layers through MES/SCADA integration, predictive maintenance, and shop-floor analytics.
Why Choose ACL Digital for End to End Industrial Automation System Engineering Services
End-to-End Engineering & Automation Expertise
End-to-end sensor-to-cloud system engineering from product design and embedded integration to edge intelligence and cloud platforms. ACL Digital enables OEMs and SIs to modernize products and systems through ACL Digital’s accelerated innovation and connected industrial engineering services.
Technology-Led Innovation
Harnessing AI in industrial automation, IIoT, edge computing, digital twins, and cloud-native architectures to build self-aware, data-driven automation systems that enable real-time decisions and autonomous operations.
Lifecycle Ownership & Faster Time-to-Market
From concept and NPI to modernization and sustainment, ACL Digital delivers full lifecycle ownership using reusable IPs, MBSE frameworks, and engineering accelerators that reduce cost, enhance reliability, and improve time-to-market.
Compliance, Safety & Cybersecurity by Design
Built-in safety and cybersecurity on demand to ensure every product is secure, compliant, and resilient for mission-critical industrial environments.
Co-Innovation Ecosystem & Engineering Partnership
In collaboration with OEM, IEM, and technology partners, ACL Digital drives joint innovation and agile delivery, turning ideas into market-ready industrial platforms and next-generation automation systems.
Industries We Serve
Enabling transformation across process, manufacturing, and emerging automation domains from sensor-to-cloud
Oil, Gas & Petrochemicals
Enabling connected asset management, digital twins, and predictive analytics to improve safety, sustainability, and performance across upstream, midstream, and downstream operations.
Power, Utilities & Renewables
Driving smart grid and renewable modernization through IoT monitoring, digital twins, and edge analytics for reliable, compliant, and efficient energy management.
Food, Beverage & Consumer Goods
Embedding intelligence into processing, packaging, and supply chain systems for real-time traceability, predictive maintenance, and sustainable production.
Industrial Equipment & Heavy Machinery
Helping OEMs design, digitize, and modernize equipment with embedded intelligence, edge connectivity, and lifecycle optimization.
Automotive & Mobility Manufacturing
Empowering OEMs and Tier-1s with AI-driven automation, robotics, and digital twins for predictive quality and Industry 4.0 compliance.
Electronics & Semiconductor Manufacturing
Driving precision automation, machine vision, and cleanroom intelligence for high yield, connected production environments.
Automation & Control OEMs
Engineering next-generation PLCs, HMIs, gateways, and edge systems with built-in intelligence, safety, and cybersecurity.
Material Handling & Logistics Automation
Building smart robotics, motion control, and edge-enabled systems for agile and connected logistics operations.
Client Impact
Intrinsically Safe Gas Transmitter with HART Integration for Hazardous Plants
ACL Digital developed a compact, low-power gas transmitter for a leading oil & gas client, designed for hazardous environments. The solution meets IS/ATEX and SIL2/3 safety standards, integrates seamlessly with existing HART-based plant systems, and delivers reliable, maintenance-friendly operation under extreme conditions.
The Challenges
- Lack of an intrinsically safe, low-power hardware platform with SIL2/3 readiness for hazardous environments
- Absence of seamless HART integration and certification-ready design, delaying compliance and plant system adoption
The Outcomes
- Delivered a reliable, low-power transmitter with seamless HART integration, ensuring extended device life and smooth plant adoption
- Achieved SIL2/3 readiness and first-cycle compliance, accelerating certification and product launch in hazardous environments
AI-Powered Industrial Fault Detection for Predictive Maintenance
ACL Digital engineered an AI-powered fault detection system for an industrial client — combining sensor data, edge analytics, and cloud-based diagnostics to identify anomalies in real time. The solution enabled predictive maintenance, reduced unplanned downtime, and improved equipment reliability across operations.
The Challenges
- Lack of real-time fault detection for vibration, temperature, and humidity in rotating equipment
- Absence of predictive diagnostics, leading to frequent unplanned downtime and higher maintenance costs
The Outcomes
- Reduced unplanned downtime by 22% with early detection of mechanical and environmental anomalies, improving overall equipment reliability
- Lowered maintenance costs and enhanced safety through actionable multi-parameter insights, enabling proactive maintenance planning and extended machinery lifecycle
Smart Wind Turbine Monitoring with Edge AI & Predictive Analytics
ACL Digital delivered a smart wind-turbine monitoring system integrating edge AI, video analytics, and predictive maintenance capabilities. The solution enabled the client to detect wildlife near turbines, trigger automated protective measures, and monitor blade and structural health—reducing downtime, improving safety, and ensuring regulatory compliance.
The Challenges
- Need for real-time detection of birds and other objects around wind turbines to prevent operational risks
- Difficulty in automating visual monitoring and triggering proactive countermeasures
- Lack of intelligent analytics for predictive maintenance decision-making
The Outcomes
- Reduced wildlife collision risks and environmental impact by enabling automated countermeasures, ensuring regulatory compliance and ecosystem protection
- Enhanced turbine uptime and lowered maintenance costs through predictive insights, minimizing unplanned repairs and downtime while extending equipment lifespan
