Capabilities Overview

Custom Process Automation & Material Handling

Batching, weighing, and controls, engineered to your process and supported for its lifetime.

Sterling Systems & Controls custom-engineers ingredient batching systems, material weighing systems, and process controls for manufacturers who need accuracy they can measure and traceability they can prove. Every system is built to your specific process — not configured from a product catalog — and supported by the same full-time engineers who designed it, without annual service contracts.

For over 50 years, Sterling has delivered complete manufacturing automation for feed milling and pet food manufacturing, baking and food processing, agriculture and grain handling, and industrial processing operations worldwide.

Our core capabilities span four areas: batching and weighing systems — from micro ingredient scales to full multi-station lines; controls and automation — including process controls, supervisory software, and legacy system upgrades; bulk bag handling — filling and unloading integrated directly into your process; and complete process systems — turnkey plantwide automation from a single accountable source.

Industrial bulk material handling system: four elevated hoppers with motors on a raised platform and yellow safety rails in a warehouse setting.

Under One Roof

Electrical

UL panel shop, PLC & HMI

Mechanical

Process & structural design

Software

.NET, FactoryTalk View ME/SE, recipe management/reporting tools, and other software platforms

Service

24/7 lifecycle support

50+

Years in batching & weighing

24/7

After-sales support. No annual contract or subscription

20+

Years avg. PM tenure

UL & cUL

Listed panel builder, US & Canada

What We Do — Core competencies, standalone or fully integrated

Batching & Weighing

Streamlined, accurate ingredient batching. Feeder sizing, bin capacity, system layout, bulk bags, and totes, backed by 50+ years of application expertise.

Controls & Automation

PLC-based systems built with an SQL database and a .NET operator interface. Recipe management, lot tracking, batch production, ERP integration, and alarm and event monitoring.

Complete Systems

From sourced equipment such as grinders, mixers, conveyors, magnets, and dust collection systems to fully autonomous systems using cobots and AMRs, Sterling engineers plantwide automation solutions tailored to your operation.

Software Applications

WebCentral Supervisory control, PMPlanR Preventative Maintenance, data management, and legacy automation upgrades, configured to your process.

Specialty Systems — Standalone modules or integrated into larger lines

Bulk Bag Handling

Custom fillers and unloaders for FIBCs, super-sacks, and totes. Integrates dust containment, magnets, bag massagers, and conveying.

Liquid Handling

Mother-tote and drum/barrel dispensing by mass flow, gain in weight, or loss in weight. Pumps, meters, and PLC/HMI controls, built for your exact process.

Bearing Condition Monitor

Alerts before shutdown on high-speed mills and classifiers. Standalone or integrated, intrinsically-safe options for Class I-III, Division 1 and 2.

Spare Parts & Service

24/7 support from the engineers who know your system. Remote or onsite, no annual contract. No upfront PO required.

Sterling Software Suite

Purpose-built for batching operations.

Standard applications, configured to your process and integrated with your controls.

WebCentral™

Browser-based supervisory control and remote operation.

PMPlanR™

Preventative maintenance planning for the full facility.

FreshStart™

Upgrade path for legacy automation, without starting over.

Industries Served

Fifty years of application expertise across processing industries.

Feed Milling
Pet Food
Baking
Chemical Processing
Nutraceutical

Cattle Feed & Pre-Blend
Food Processing
Rubber Compounding
Mineral Processing
Other Industrial

How We Work — From first call to 24/7 lifecycle support

01 · Analyze

Consult your staff

We engage with operators, engineers, and plant management to define project objectives and constraints.

02 · Develop

Engineer the solution

Mechanical and control systems designed in-house to achieve your rate, accuracy, and footprint.

03 · Deliver

Build, test, start up

Panel build, mechanical assembly, system testing, onsite install and operator training.

04 · Support

24/7

Customer service for the life of the install.