Build-to-Print Tamp Machines for a Composite Decking Manufacturer
A Leading Composite Decking Manufacturer needed six tamp machines built to its own engineering drawings — and needed every one to arrive ready to run on its existing control logic. J+H Automation Solutions fabricated all six units, wired and tested every field device, and built a dedicated test control panel on the plant's Schneider Electric Modicon platform so each machine could be factory acceptance tested in Hackett, Arkansas using the customer's own PLC program before it ever left the shop.
See the Equipment in Action
Composite decking boards moving through tamp machine and board handling equipment — roller conveyor, pneumatic board pusher, and tamp roller — on the manufacturer's production line.
Footage from the customer's composite decking production line, July 2025.
The Challenge & the J+H Solution
The manufacturer had the machine design in hand. What it needed was a fabrication and controls partner that could turn those drawings into six consistent, production-ready machines — and prove each one worked on the plant's own control system before it shipped, so start-up on a running line would be fast and predictable.
The Challenge
- Six identical tamp machines needed, built exactly to customer-supplied drawings
- Machines had to run on the plant's existing Schneider Electric Modicon control logic
- Field devices and I/O had to be correct on arrival — not debugged on the plant floor
- Start-up risk and downtime on a live production line had to be minimized
- The plant needed shop capacity to build multiple units to a consistent standard
The J+H Solution
- Fabrication and assembly of all six tamp machines per the customer's drawings
- Field devices, IO-Link sensor networks, and wiring installed on every machine
- Dedicated test control panel built around a Modicon M580 processor
- Every I/O point and field device wired and tested against the test panel
- Factory acceptance testing in Hackett, AR using the plant's current PLC program
From Drawings to Proven Machines
Every machine moved through the same three-stage process, so all six arrived built, wired, and validated to one standard.
Build-to-Print Fabrication
J+H fabricated and assembled each tamp machine to the customer's engineering drawings, with layout drawings submitted for review and approval before release to fabrication.
Field Device & I/O Wiring
Each machine was outfitted with its field equipment — IFM IO-Link masters and input modules, SMC IO-Link communication, Telemecanique ultrasonic sensors, cylinder position sensors, NEMA 4X safety disconnects, and Type 12 wireway — then fully wired.
Factory Acceptance Testing
Machines were connected to the J+H-built test control panel and run on the customer's current PLC program from its existing machines — proving every device, drive, and I/O point at the Hackett, Arkansas facility before shipment.
What J+H Fabricated, Wired & Tested
The scope covered six complete machines plus the controls hardware needed to prove them out — all built and tested under one roof.
Six Build-to-Print Tamp Machines
Fabrication and assembly of six tamp machines to the manufacturer's supplied drawings — built to a consistent standard across every unit, with up-to-date layout drawings furnished at project close.
Modicon M580 Test Control Panel
A Type 12 enclosure with flange-mount disconnect, voltage presence indicator, Allen-Bradley safety contactors, a Schneider Electric Modicon M580 processor on a 12-slot Ethernet backplane, discrete input and relay output modules, a Wago Ethernet switch, and three PowerFlex 525 VFDs.
IO-Link Field Equipment Package
Per-machine field equipment including IFM IO-Link masters with EtherNet/IP, IO-Link input modules, SMC EX260 IO-Link communication, Telemecanique ultrasonic sensors, magnetic cylinder position sensors, and Hubbell NEMA 4X non-fused safety disconnects.
Full I/O Checkout & FAT
Every field device and I/O point wired and tested to the test panel, followed by factory acceptance testing using the customer's existing PLC program — so the machines were validated on the same logic they run in production.
Results: Machines That Arrive Ready to Run
Testing on the plant's own control logic moved the debugging out of the customer's facility and into J+H's shop.
Delivered Performance
- Six tamp machines built to customer drawings and a single consistent standard
- 100% of field devices and I/O wired and tested before shipment
- Each machine proven on the customer's current PLC program during FAT
- Controls validated on the plant's own Modicon platform — no control-system conversion
Business Impact
- Reduced start-up risk and on-site troubleshooting on a running production line
- Faster integration — machines arrived pre-wired and pre-validated
- Added fabrication capacity without tying up the plant's own maintenance team
- One-year J+H parts and labor warranty on all J+H-manufactured components
Built for Building Products Manufacturing — and Beyond
This project reflects the custom machinery J+H builds for building products and composite materials manufacturers: production equipment fabricated to the customer's design or J+H's own, fully wired, and factory acceptance tested before shipment so plants can integrate new machines with minimal disruption.
The same shop-tested approach extends across J+H's controls & integration work — on Allen-Bradley, Schneider Electric Modicon, and other platforms — serving manufacturers nationwide from facilities in Hackett, Arkansas and Hockley, Texas.
Frequently Asked Questions
What did J+H build for this composite decking manufacturer?
J+H Automation Solutions fabricated six tamp machines to the manufacturer's own engineering drawings, installed and wired all field devices and I/O on each machine, and built a dedicated test control panel so every machine could be proven out at J+H's Hackett, Arkansas facility before shipment.
Can J+H build machines to our drawings?
Yes. This project was build-to-print: the customer supplied the machine drawings and J+H handled fabrication, assembly, field device installation, and wiring for all six units. J+H submits layout drawings for review and approval before release to fabrication, and furnishes up-to-date layout drawings of all equipment at project close.
How were the machines tested before shipment?
J+H built a test control panel around a Schneider Electric Modicon M580 processor — the same platform the plant runs — with three Allen-Bradley PowerFlex 525 drives, safety contactors, and an Ethernet network. Every field device and I/O point was wired and tested, then each machine went through factory acceptance testing (FAT) in Hackett, Arkansas using the customer's current PLC program from its existing machines.
Does J+H work with Schneider Electric Modicon PLCs, or only Allen-Bradley?
J+H works with the control platform your plant already standardizes on. On this project the test panel was built around a Schneider Electric Modicon M580 with IFM IO-Link masters and modules, SMC IO-Link communication, Telemecanique ultrasonic sensors, and Allen-Bradley PowerFlex 525 drives — so the machines were validated on the same hardware and logic they would run in production.
Does J+H Automation Solutions build custom machinery for building products manufacturers?
Yes. J+H Automation Solutions designs, fabricates, wires, and tests custom machinery and material handling equipment for building products and other manufacturers nationwide from facilities in Hackett, Arkansas and Hockley, Texas — with factory acceptance testing performed before shipment. Contact sales@jhautomationsolutions.com or call (479) 638-8398 to discuss your application.
Have the Drawings? We'll Build and Prove the Machines.
From build-to-print fabrication to full I/O checkout and factory acceptance testing on your own PLC program, J+H Automation Solutions delivers machines that arrive ready to run.
Request a Consultation Call (479) 638-8398