We work on most brands of PLCs, HMIs and VFDs

Meet Saga Automation

The most important part of hiring a systems integrator is the engineer(s) that deliver your automation.

Tom Ludwig is the owner and consultant at Saga Automation. From 2001 to 2018 he was a plant engineer at three manufacturing plants making shampoo, fruit juice and beer. He has run about a hundred projects over those 18 years. Before that he worked at OEM equipment manufacturers and control systems integrators. What that wealth of experience means is that Saga Automation understands what plant and operations managers, engineering and maintenance managers, plant engineers and maintenance technicians go through at their manufacturing plants to keep their automation running and to improve on it.

Saga Automation is dedicated to helping manufacturers in the mid-Atlantic states with their automation needs. Many manufacturing plants already have a systems integrator or two that they are happy with, but others call us and say their systems integrator is not as responsive enough or is not price competitive. Saga Automation was founded in 2018 and relocated to Wilmington, DE in 2022.  Saga is regrowing it’s customer base in the new location and is hungry for your business, and will endeavor to out-work the competition to earn your business.

Values are a key driver at Saga Automation. While excellent technical execution of automation is our service promise, honesty and integrity are cornerstones to attracting and keeping customers. When we meet the first time, the goal is to listen to you and hear what your needs are. Sometimes Saga Automation won’t be a good match to your needs and we will try and refer you to a better resource if that is the case, but most of the time Saga Automation will be more than capable of handling your needs. We have worked on many brands of PLC & HMI, designed new panels, and migrated obsolete hardware to new hardware over the years.

Finally we are a Wilmington, Delaware control systems integrator.  A good control systems integrator should be available to help you quickly when you need it.  That means we should be within three hours travel time of your location to best service you, though there can be exceptions made.  We answer the phone 7/24.  Thank you for your interest in Saga Automation. Let us show you our value.

Tom Ludwig

Tom Ludwig

Owner / Engineer

Tom Ludwig graduated High School in Delaware and went to UC San Diego from 1987 to 1991.  He lived and worked in California from 1987 to 2022, before coming home to Delaware in 2022.  He is married with one child.  He enjoys wargaming, reading, travel, politics and business and real estate.

This picture is taken in Italy in a region known as the Cinque Terre with the very blue Mediterranean sea as a backdrop.

We work on most brands of PLCs, HMIs and VFDs
Our Work

Projects

We work on most brands of PLCs, HMIs and VFDs

Brewing Projects

  • Implemented many projects in the process department that makes beer.
  • Led four projects to replace 60% of the software in the brewing department.
We work on most brands of PLCs, HMIs and VFDs

Machine Optimization

  • Case Packer with too much downtime and wasn’t fixed after two OEM visits.  Had numerous jams in corrugate pick-up operation.
  • Studied PLC code and made recommendations so that when OEM came back they agreed to changes.
  • Machine availability went from 68% to 95% with changes to four PLC timers.
We work on most brands of PLCs, HMIs and VFDs

Utilities Projects

  • At three different plants implemented air compressor projects.  Compressed air at many manufacturers is responsible for 10 to 30% of energy usage, and there are ways to save money usually.
  • Also worked on water softeners, gas turbines, waste water, fresh water, ammonia, data reporting and many other projects.  Nearly all of which have sustainability or cost savings justifications.
We work on most brands of PLCs, HMIs and VFDs

Packaging Projects

  • Large Projects: Have reconfigured entire packaging lines at multiple plants.
  • Medium Projects: Adding a new piece of packaging equipment is oftentimes a $10,000 to a million dollars.  Tight timelines and big expectations for the new equipment are the norm.
  • Small Projects: Packaging lines are usually from 3 to 10 pieces of machinery connected by conveyor.  Small problems lead to production, material or labor losses.  Fixing the tiniest of issues can have major benefits such as the packer machine optimizaiton example above.  Truly small projects are usually the lowest hanging fruit.