General Manufacturing Service

General Manufacturing Controls Service | Mid-South | Memphis Control Center
General Manufacturing Service

General Manufacturing
Controls & Steam Service — Mid-South

The Mid-South is one of the country's most active manufacturing regions. Tennessee alone has hundreds of active manufacturing facilities. Alabama is home to Toyota's largest engine plant in North America. Volkswagen operates in Chattanooga. Nissan in Canton, Mississippi. Big River Steel in Osceola, Arkansas. Every one of those facilities runs controls systems, steam equipment, and motors that need service. Memphis Control Center has supported manufacturing facilities across the Mid-South since 1967.

Mid-South since 1967 TN · AR · MS · AL · LA Same-day parts shipping Emergency or planned
Service Coverage: Tennessee Arkansas Mississippi Alabama Louisiana Gulf Coast

A Major Manufacturing Region — Since 1967

Tennessee, Alabama, Mississippi, Arkansas, and Louisiana are home to a diverse manufacturing base spanning automotive, steel, food processing, chemicals, electronics, aerospace, and general industrial production. The region is one of the most active manufacturing corridors in the South.

The Mid-South manufacturing base has expanded significantly over the past three decades. Toyota's Huntsville, Alabama facility is Toyota's largest engine producer in North America. Volkswagen has operated its North American production hub in Chattanooga, Tennessee since 2011. Nissan has a major assembly plant in Canton, Mississippi. U.S. Steel's Big River Steel Works in Osceola, Arkansas is one of the largest steel mills in the country. PPG Industries opened a $300 million paint and coatings plant in Loudon County, Tennessee in 2024. Toyota's Huntsville plant received an additional $282 million investment in 2024 to introduce new drivetrain production lines.

Beyond these marquee names, the region has hundreds of mid-size and smaller manufacturing operations — metal fabrication shops, plastic injection molders, textile operations, food processors, printing and packaging plants, and general industrial facilities. Every one of them has controls systems, steam equipment, motors, and instrumentation that need to run. Memphis Control Center has been supplying the parts and service support to keep those systems running since 1967.

55+
Years in Manufacturing
Serving manufacturing facilities across the Mid-South since 1967. We know the equipment in your plant.
2 PM
Same-Day Parts Cutoff
Critical controls, boiler parts, and instrumentation ship same day by 2 PM CT. Production downtime has a direct cost.
5
States Covered
Tennessee, Arkansas, Mississippi, Alabama, and Louisiana — the full Mid-South manufacturing corridor.

Manufacturing Types in Our Region

Automotive & Tier Suppliers
Toyota Huntsville AL (Toyota's largest engine plant in North America), Toyota Blue Springs MS (Corolla assembly), Volkswagen Chattanooga TN, Nissan Canton MS, and hundreds of Tier 1 and Tier 2 suppliers throughout the region. Precision controls and high-uptime requirements.
TN · AL · MS · AR
Steel & Metals
U.S. Steel’s Big River Steel Works in Osceola, Arkansas and Steel Dynamics’ Columbus, Mississippi complex are two of the most advanced steel facilities in the country. Nucor also operates in the region, including facilities in Decatur, Alabama. High-intensity process controls and utility steam systems.
AR · AL · MS
Electronics & Aerospace
Huntsville, Alabama is home to major aerospace and defense manufacturing. Memphis has significant distribution and light manufacturing. Electronics assembly operations throughout Tennessee and Alabama.
AL · TN · AR · MS
Plastics & Rubber
Injection molding, extrusion, and rubber products manufacturers throughout the region. Process heating controls, cooling water systems, and machine controls all require reliable service.
TN · AL · MS · AR · LA
Printing & Packaging
Memphis is one of the largest logistics and distribution hubs in the country, with significant printing and packaging operations. Steam and compressed air systems, conveyor controls, and utility boilers.
TN · MS · AR · AL · LA
General & Light Industrial
Metal fabrication, woodworking, textile, paint and coatings, and general manufacturing operations throughout all five states. Utility boilers, compressed air systems, machine controls, and VFDs all need ongoing service.
TN · AR · MS · AL · LA

Manufacturing Controls & Steam Service Scope

From utility boiler rooms to machine control panels and VFD drives on production equipment — the full scope of controls and steam system service we support in manufacturing facilities across the Mid-South.

Utility Boiler & Steam System Service

Most manufacturing plants run a utility boiler for space heating, process steam, humidification, or cleaning. When the boiler goes down in a manufacturing facility, it affects production, building comfort, and process operations simultaneously.

Steam boiler inspection, repair & startup
Burner control service & lockout diagnosis
Low water cutoff replacement & testing
Boiler gasket replacement (Topog-E® stocked)
Steam trap survey & replacement
Annual inspection prep & documentation

Machine Control & PLC Service

Manufacturing equipment runs on PLCs, machine controls, and motion control systems. When a machine faults out, production stops immediately. Fast diagnosis and parts availability are what keep downtime short.

PLC fault diagnosis & program backup
I/O module replacement & rack service
HMI service & replacement
Control panel inspection & component replacement
Contactor, relay & overload replacement
Legacy PLC upgrade planning & support

VFD Service & Replacement

Variable frequency drives on fans, pumps, conveyors, and production equipment are one of the most common points of manufacturing downtime. VFD failures are often heat-related and almost always urgent.

VFD fault diagnosis & parameter backup
Drive replacement & parameter restore
VFD startup & commissioning
Input/output filter & reactor service
Motor-drive system troubleshooting
Legacy drive upgrade & replacement

Motor Control Center (MCC) Service

MCCs are the central nervous system of a manufacturing plant’s motor system. Failures in MCC buckets take down multiple pieces of equipment at once and require fast, knowledgeable response.

MCC bucket inspection & maintenance
Starter & contactor replacement
Overload relay selection & replacement
Circuit breaker testing & replacement
Soft starter installation & service
MCC modernization & retrofit

Instrumentation & Process Controls

Process manufacturing — plastics, coatings, chemical, food — depends on accurate measurement and control of temperature, pressure, and flow. Out-of-calibration instruments produce off-spec product and waste material.

Temperature sensor (RTD/thermocouple) calibration
Pressure transmitter calibration & replacement
Flow meter service & calibration
Control valve & positioner service
4-20mA loop calibration & HART configuration
Process controller service & replacement

Planned Maintenance & Shutdown Support

Planned maintenance windows are the best opportunity to replace aging controls, test safety devices, and stage critical spares. We help manufacturing facilities plan ahead so emergency failures happen less often.

Shutdown parts staging & kitting
LWCO replacement at recommended intervals
Pre-season boiler startup & inspection prep
Critical spare inventory consulting
VFD parameter backup before planned replacement
Control system upgrade planning & specification
Production line down? Controls or boiler failure? Parts ship same day by 2 PM CT from Memphis.

Common Manufacturing Controls Problems

The most common controls, boiler, and electrical issues we support in manufacturing facilities across the Mid-South — causes and where to start.

Controls Troubleshooting — General Manufacturing

Reference for plant maintenance teams. Follow your facility’s LOTO and safety procedures before working on any electrical or control equipment.

Utility boiler burner lockout — no heat or steam
A boiler burner lockout in a manufacturing plant affects space heating, process steam, and hot water simultaneously. Check the burner relay module display for a fault code — on Honeywell RM7800 controls, the KDM display shows a specific fault code that identifies the cause (gas valve failure, ignition failure, flame failure, etc.). Common manufacturing plant causes: clogged gas orifice or strainer (especially on propane systems), dirty UV flame scanner (combustion sight glass fouled), or a tripped gas train pressure switch. Always complete the required pre-purge before relighting — never bypass the purge timer regardless of urgency to restore heat.
RM7800 relay modules, flame amplifiers, and M&M LWCOs stocked — same-day shipping by 2 PM CT.
VFD fault on production conveyor or exhaust fan
VFD faults in manufacturing environments are most commonly heat-related in the summer and moisture-related in wet process areas. Check the drive fault code first. For overcurrent: verify the load is free to turn (no mechanical jam), check the ramp time parameters (too fast an acceleration on a loaded conveyor trips OC), and verify three-phase power supply balance. For overtemperature: check the VFD’s air filter and cooling fan — manufacturing environments with dust, lint, or airborne fibers clog VFD filters quickly. Many manufacturing plant VFDs need filter cleaning monthly rather than annually. If the drive shows a ground fault, megger the motor before restarting to avoid damaging the replacement drive.
Common VFD replacements for manufacturing conveyor and fan applications stocked — call with drive nameplate.
PLC in fault — machine stopped, fault code on display
Before touching anything, connect programming software and read the fault log — most PLCs store several recent faults with timestamp and module information. Common manufacturing PLC faults: I/O module fault from a shorted field device (check the devices wired to that module), power supply fault (check incoming voltage and DC output), or memory fault from a dead battery (replace battery immediately and reload the program from backup). If the PLC fault is intermittent (randomly dropping out), check for power quality issues — voltage sags from large motor starts nearby are a common cause of Allen-Bradley and other PLC random resets in manufacturing environments. Always maintain a program backup — a PLC without a backup program is a parts failure away from a multi-day outage.
Allen-Bradley, Siemens, and other common PLC I/O modules and power supplies — call with part number for same-day shipping.
Overload relay tripping repeatedly on production motor
A repeatedly tripping overload relay means the motor is drawing more current than the overload setting. Identify why before resetting again — repeated resets without correcting the cause damage the motor windings. Check: (1) Is the mechanical load heavier than normal? Product buildup on a conveyor, worn bearings, or a seized coupling all increase motor load. (2) Is the overload relay set correctly? The overload must be set to the motor nameplate FLA, not a round number. (3) Is one phase of the three-phase supply missing or low? Single-phasing causes the motor to draw excessive current on the remaining two phases and is very hard on the motor. Check all three phase voltages at the starter.
Allen-Bradley, Siemens, and Schneider overload relays in stock — call with starter model and FLA for verified replacement.
Low water cutoff not tripping during boiler blowdown test
A low water cutoff that does not trip when the boiler is blown down is a safety failure — do not return the boiler to service. The LWCO’s purpose is to shut off the burner if water level drops dangerously low. If it won’t trip during the blowdown test, it won’t protect the boiler in a real low-water event. Common causes: float chamber fouled with scale or sediment (the float is stuck), the float itself is waterlogged or damaged, or the electrical switch inside has failed. After cleaning the chamber and performing a float drop test, if the control still does not trip reliably, replace it. Per McDonnell & Miller MM-825(A) guidelines, all float-type LWCOs should be replaced at a maximum of 10 years regardless of condition.
M&M Series 67, 150S, 157S, PS-800 in stock — same-day shipping. Replace, don’t reset and hope.
Control panel running hot — components overheating
Hot control panels in manufacturing plants most commonly result from failed or inadequate cooling, increased heat load from added equipment, or blocked ventilation. Check the panel cooling equipment: is the panel air conditioner or heat exchanger running? Is its setpoint correct? Are the filters clean? Check for added equipment — a VFD or additional contactors added to the panel without updating the thermal design increases heat load. Thermal imaging inside the panel (with power on and LOTO-safe precautions) reveals hot spots on overloaded conductors or failing components before they cause a catastrophic failure. Loose terminal connections are a common heat source in manufacturing plants where vibration is present.
Hoffman and Rittal panel cooling equipment, panel fans, and thermostat controls available — call with panel dimensions.

Equipment Guides for Manufacturing Facilities

Our technical guides cover the boiler controls and steam system components most commonly found in manufacturing facility boiler rooms.

Manufacturing Controls Service Across the Mid-South

We support manufacturing facility controls, boiler, and instrumentation service throughout the following areas.

Memphis
Tennessee
Nashville
Tennessee
Knoxville
Tennessee
Chattanooga
Tennessee
Loudon
Tennessee
Little Rock
Arkansas
Osceola
Arkansas
Fort Smith
Arkansas
Jonesboro
Arkansas
North Little Rock
Arkansas
Jackson
Mississippi
Canton
Mississippi
Tupelo
Mississippi
Columbus
Mississippi
Hattiesburg
Mississippi
Huntsville
Alabama
Birmingham
Alabama
Montgomery
Alabama
Tuscaloosa
Alabama
Decatur
Alabama
New Orleans
Louisiana
Baton Rouge
Louisiana
Shreveport
Louisiana
Lafayette
Louisiana
Monroe
Louisiana

Chattanooga TN (Volkswagen), Huntsville AL (Toyota), Canton MS (Nissan), and Osceola AR (Big River Steel) are highlighted as major manufacturing anchors. Loudon County TN now home to a PPG Industries paint and coatings plant. Columbus MS is home to Steel Dynamics’ flat-rolled steel complex (3.4 million tons annual capacity) and Aurora Flight Sciences (a Boeing company) aerospace composites manufacturing.

Manufacturing Facility Controls Issue?

Tell us your plant type, what’s down, and where you are. Emergency breakdown or planned maintenance — we can help either way.

Frequently Asked Questions

What types of manufacturing facilities do you support in the Mid-South?
We support manufacturing facilities of all types and sizes — from small job shops to large automotive and steel plants. The Mid-South has a diverse manufacturing base including automotive assembly and tier suppliers (Toyota Huntsville, Volkswagen Chattanooga, Nissan Canton), steel (Big River Steel Osceola AR), food and beverage processing, chemical manufacturing, printing and packaging, plastics and rubber, electronics and aerospace (Huntsville AL), and general light and heavy industrial operations. If your facility has a boiler, controls systems, motors, or process instrumentation — we can help.
Do you stock parts for manufacturing plant utility boilers?
Yes — we stock the most common manufacturing plant boiler controls including McDonnell & Miller low water cutoffs (Series 67, 150S, 157S, and PS-800), Honeywell RM7800 series burner controls and flame amplifiers, and Topog-E boiler gaskets in Series 180 and 450. Orders placed by 2 PM CT ship same day from Memphis. A utility boiler failure in a manufacturing plant takes down space heating, process steam, and washdown water all at once — we treat these calls with appropriate urgency.
What is the most common VFD failure in manufacturing plants during the summer?
In our experience across the Mid-South, overtemperature is the most common VFD failure cause during summer months in manufacturing facilities. The Mid-South runs hot in the summer — ambient temperatures inside manufacturing plants often exceed 95–100°F during peak summer weeks. Most VFDs are rated for a maximum ambient of 40°C (104°F) without derating. When the air inlet filter is even partially clogged, actual temperature inside the drive can significantly exceed ambient. VFD filters in dusty or fibrous manufacturing environments (automotive body shops, textile mills, woodworking shops) can clog in weeks rather than months. The single most effective VFD preventive maintenance item is regular filter cleaning and an annual check of the internal cooling fan.
How often should manufacturing plant low water cutoffs be replaced?
McDonnell & Miller’s MM-825(A) catalog recommends replacing all major float-type low water cutoffs — including Series 67, 150S, and 157S — at a maximum of 10 years, regardless of apparent condition. In a manufacturing plant where the boiler is critical to operations, many boiler technicians and inspectors recommend a shorter replacement interval. The test that matters is the blowdown test: blow down the LWCO while the boiler is firing and verify that the burner shuts off. If it doesn’t shut off, replace the control immediately and do not return the boiler to service. A LWCO that won’t trip during blowdown will not protect your boiler in a real low-water event.
Can you help us build a critical spare parts inventory for our plant?
Yes — one of the most valuable conversations we have with manufacturing customers is about critical spares. The question is: if this part fails at 2 AM on a Friday before a holiday weekend, how long can your plant be down? For parts with long lead times or that are on aging/obsolete platforms, a spare on the shelf is insurance against an extended outage. Common critical spares we help manufacturing plants identify and stock: a spare PLC CPU or I/O module for their production-critical machines, VFD replacements for motors on the critical path, a spare LWCO and burner relay module for the utility boiler, and overload relays for critical motor feeders. Call us and we’ll walk through what makes sense for your facility.
Do you support planned shutdown and maintenance windows?
Yes — planned maintenance is where the best facilities prevent the emergency breakdowns. Common items we help manufacturing plants stage for annual or semi-annual maintenance windows include Topog-E gasket kits for their utility boilers, LWCO replacements on schedule, VFD filter kits, contactor and overload relay replacements for high-cycle motor feeders, and instrumentation calibration kits. Contact us ahead of your planned maintenance window — even a few weeks in advance — and we’ll make sure the right parts are on hand. Same-day emergency shipping is available when planned maintenance turns into an unexpected emergency.

Need Manufacturing Controls Service in the Mid-South?

Memphis Control Center has been supporting manufacturing facilities across Tennessee, Arkansas, Mississippi, Alabama, and Louisiana since 1967. Tell us what you need — we’ll get you taken care of.

Family owned since 1967 TN · AR · MS · AL · LA Same-day parts by 2 PM CT Emergency or planned
Manufacturing controls service — Mid-South

For emergencies, outside of business hours, call #901-604-7069