Technical Q&A with Mike Jordan

Material drying using vacuum technology has opened another avenue to further reduce scrap and downtime.

At Summit Systems, we’ve integrated these innovations into our equipment and system designs — offering customers enhanced process control, energy savings, and reduced downtime. Our solutions now deliver real-time insights and adaptive control, allowing operators to fine-tune processes with greater accuracy.

We’re also developing modular, scalable systems to meet shifting production demands. These upgrades don’t just boost efficiency; they help our customers make more informed decisions, streamline operations, and work more sustainably.

2. How is Summit Systems addressing the challenges of integrating legacy equipment with modern automation and data-driven systems?

Integrating legacy equipment with modern automation is one of the biggest challenges manufacturers face, especially when dealing with older systems. We’ve developed a flexible, modular approach that allows us to retrofit existing machinery with smart sensors, PLC upgrades, and communication interfaces. This enables real-time data capture and seamless integration with newer Industry 4.0 platforms.

This approach often significantly reduces the capital cost of a project. Summit is committed to reusing existing equipment by integrating any non-critical components that are perfectly functional. While many suppliers recommend a complete replacement—including equipment that still works—we focus on preserving value. For example, a 15-year-old dryer may need replacing, but the hopper can still be used, offering big savings.

Our engineering team works closely with customers to assess compatibility and ensure smooth implementation with minimal disruption. We also provide tailored control systems and cloud-based monitoring tools that unify data from both old and new equipment. The result is a connected, more efficient production environment—without the cost and downtime of full system replacement.

3. With increasing pressure for sustainable manufacturing, how is automation playing a role in reducing waste, energy use, and environmental impact in plastics processing?

Sustainability is no longer optional—it’s an essential part of modern manufacturing. Automation plays a critical role in reducing the environmental impact of plastics processing. By using advanced sensors, smart metering, and energy-efficient controls, automated systems help monitor and minimise material and energy waste at every stage of production.

Summit supplies equipment that precisely manages raw material consumption, ensuring accurate dosing, recycling, and minimal over-processing. This significantly reduces scrap rates, lowers energy usage, and enhances overall process stability. We also offer solutions that help customers track their carbon footprint in real-time, so they can make smarter decisions and meet environmental targets more easily.

By integrating automation with sustainability goals, manufacturers can boost efficiency and reduce costs while meeting increasingly strict regulatory and customer demands. Our systems empower businesses to make cleaner, data-driven choices that benefit both profit and planet.

4. What role does predictive maintenance and real-time monitoring play in the efficiency of automated plastics processing lines, and how do your systems enable this?

The truth is, when something goes wrong and production goes down it’s disastrous. I ran a mould shop for 5 years, so I know firsthand that you need urgent solutions.

Predictive maintenance and real-time monitoring are essential for keeping plastics processing lines efficient and reliable. Instead of reacting to failures, manufacturers can now anticipate them—cutting downtime, reducing waste, and improving product quality.

We use smart sensors and data tools that track variables like temperature, pressure, and energy use. These metrics are analysed in real time, helping spot issues early and schedule maintenance before breakdowns occur. We also offer dashboards and alerts that give teams full visibility, even remotely. This improves responsiveness and keeps systems running at peak performance.

BUT, we all know that the best solution is having a magically appearing engineer at the ready 24/7. We also know this is not possible, unless you have a really well-trained team, but this is rare due to the cost and availability of such talents, so we have worked very hard to make this a priority function.

We offer full training for those who have the rare talent but backed up by the only genuine 24/7 service team.

Summit Systems remains at the forefront of plastics automation, combining innovation and experience to drive smarter, more sustainable manufacturing. As Mike notes, the future is about staying connected, efficient, and ready to meet the evolving needs of the industry.