PSA: A Leader in Automation & Systems Integration
PSA Systems (PSA) is a national engineering and custom manufacturing firm specializing in robotic systems integration, custom automated machinery, drives and controls, and PLC projects. With decades of experience in automation, engineering, and fabrication, PSA delivers turnkey solutions across multiple industries.
When a munitions manufacturing facility needed to modernize its production process, they turned to PSA. The facility had been operating with outdated equipment—some systems dating back 20 to 40 years. Years of continuous production with minimal maintenance had left systems worn out, inefficient, and difficult to scale. As demand increased, these aging processes became a bottleneck, limiting efficiency and slowing output.
A Facility in Need of Modernization
The facility had a clear vision for modernization, focusing on automation and improved production flow. One key requirement was a conveyor-fed and conveyor-outfeed system that would integrate with their new automation process. However, the specifics of designing and implementing this system were left to PSA.
To execute the project, PSA needed a conveyor partner that could deliver a seamless, high-performance material handling system—and that’s where we came in.
Why PSA Needed a Conveyor Partner
PSA’s expertise in automation and robotics allowed them to optimize how munitions were loaded and unloaded, but the entire system’s efficiency depended on how materials moved between processes. A custom conveyor solution was critical—one that integrated directly with PSA’s robotic automation while meeting strict zoning, load distribution, and throughput requirements.
PSA selected Power Pack Conveyor Company because of our ability to engineer conveyor systems for complex, high-precision environments. They didn’t just need a supplier—they needed a partner who could collaborate from the design phase onward, ensuring that the conveyor system would seamlessly support their automation strategy.
By partnering with us, PSA could focus on its expertise in robotics and automation while we engineered a custom material handling solution tailored to the facility’s needs.
Collaborating on a Seamless Solution
From the outset, PSA and our team worked side by side to co-design a conveyor system that complemented the automation strategy. By combining PSA’s knowledge of robotics and process flow with our expertise in conveyor engineering, we developed a system that optimized throughput while eliminating inefficiencies.
Our contributions included:
- Customizing conveyor layouts to align with PSA’s automation strategy.
- Optimizing material flow to prevent bottlenecks.
- Ensuring smooth transitions between robotic handling and conveyor movement.
- Bringing material handling expertise that allowed PSA to focus on their core strengths—automation and robotics.
“PPCC became an extension of our engineering team, which from a business development and partner standpoint is very important to PSA. Having a partner that can step up when needed and work closely with us is critical—it streamlined the entire engineering design and layout process.” – Joe, PSA
By owning the conveyor design and engineering, we eliminated the need for PSA to develop conveyors internally, allowing them to stay focused on robotic material handling while we handled the material transport system.
A Partnership That Delivered Results
The integration of PSA’s automation technology with our conveyor systems has significantly transformed the facility’s production capabilities. The modernization effort has led to:
- More than doubled production output, exceeding modernization goals.
- Significantly reduced downtime through smoother material flow.
- Eliminated outdated manual processes, increasing efficiency.
- A scalable system that meets both current and future production demands.
This success is a direct result of the synergy between PSA’s automation expertise and our material handling solutions. By working together, we developed a system that neither company could have achieved alone.
Overcoming Challenges with a Trusted Partner
No large-scale automation project is without challenges, but our strong working relationship with PSA ensured that obstacles were addressed quickly and efficiently.
“Whenever we faced an engineering challenge, PPCC was immediate with solutions. They understood that adjustments happen and worked with us to refine the system without pushing costs through the roof. That level of flexibility and responsiveness made a huge difference.” – Ed, PSA
What made the difference was trust and responsiveness. When PSA needed adjustments, they didn’t have to wait days for answers—they could call us directly, and we worked together to find solutions in real-time. This level of collaboration kept the project on track and reinforced the value of having a reliable, knowledgeable partner.
A Foundation for Future Collaboration
As this project continues to evolve, our partnership with PSA has only grown stronger. The collaboration has deepened our understanding of each other’s processes, laying the groundwork for continued innovation in future projects.
“It’s a relationship business… finding partners that are growing, trustworthy, and a good fit for us is key. PSA is the perfect partner from that standpoint.” – Dan, PPCC
For PSA, having a trusted conveyor partner means they can execute complex automation projects knowing their material handling systems will meet the highest standards.
For our team, working alongside PSA has strengthened our ability to engineer conveyor solutions that seamlessly integrate with cutting-edge automation. This partnership has challenged us to refine our designs, improve system efficiency, and develop even more advanced solutions for high-precision environments.
This collaboration isn’t just about one project—it’s about building a long-term partnership that continues to drive innovation and efficiency in manufacturing.
