Industrial Controls in Houston, TX — The Software and Panels That Make Systems Run
Lone Star Automated Systems has provided electrical controls and PLC programming services for production, manufacturing, and warehouse/distribution projects for decades — from complete control systems for new lines to the upgrades and modifications that integrate new equipment into old ones.
From Field Device to Warehouse Software — One Integrated Stack
Every automated system runs on three layers. At the bottom, field devices — photo eyes, scanners, motors, drives, and operator stations — sense and act. In the middle, the PLC and control panel make the split-second decisions: start, stop, divert, accumulate, reject. At the top, logistics software decides what should happen next and keeps the record.
Lone Star works across all three layers — hardware, field devices, and software — which is what makes controls-led integration work: the sorter, the palletizer, and the WMS all speak the same language because one team wired, programmed, and mapped them.
Controls is also where existing plants get new life: upgrades to existing controls, or the modifications required to integrate new equipment, without replacing what already works.
Controls Work We Deliver
PLC Programming & Control Panels
From providing upgrades to existing controls, to the modifications required to integrate new equipment, Lone Star assists with the hardware, field devices, and software — panels built, programs written, devices wired, and lines commissioned as one scope.
Checkweigh, Vision & Scale Systems
A full line of cutting-edge checkweigh systems, box openers, inline scales, manifest systems, in-motion scales, sorters, and sortation systems — every package weighed and verified at line speed, with out-of-tolerance product rejected automatically.
Light-Directed & Voice Solutions
Streamlining order fulfillment through the latest technologies: pick-to-light, put-to-light, pack-to-light, and voice-directed picking — plus RF picking for scan-confirmed accuracy. Clients improve service levels, achieve superior order quality, and advance their market positions.
Print & Apply, RFID & Container Routing
Complementary applications that tie identification to action: container routing, RFID on demand, print & apply labeling, and high-speed sortation — so every carton is identified, labeled, and sent to the right destination automatically.
WMS & TMS — Supply Chain Execution That Directs the Floor
Delivering unique logistics solutions supporting production and distribution operations for manufacturers, distributors, and 3PL providers is our goal — complete logistics management through a suite of supply chain execution applications.
Advanced warehouse management (WMS) and transportation management (TMS) systems enable companies to automate their inbound order processes, inventory control, and outbound distribution activities using RF, barcode, and auto-ID technology.
The systems prioritize, direct, and confirm activities based upon the real-time conditions and constraints of space, equipment, inventory, and personnel — the intelligence layer above the conveyors and storage systems we install.
By leveraging extensive industry experience, proven methodologies, and advanced logistics technologies, organizations continually realize increases in asset utilization, accuracy, quality, and compliance.
The same gains lower overall production and distribution costs — the software pays for itself in throughput and error reduction.
Activities prioritized, directed, and confirmed against live conditions — space, equipment, inventory, and personnel — not yesterday's plan.
Controls & PLC FAQs
What controls services does Lone Star provide?
Electrical controls and PLC programming for production, manufacturing, and warehouse/distribution projects — complete control systems for new lines, plus upgrades of existing controls and the modifications required to integrate new equipment, across hardware, field devices, and software.
Can you upgrade existing control panels instead of replacing them?
Yes — much of our controls work is exactly that: upgrading existing controls or modifying them to integrate new equipment, so your existing investment keeps working with the new.
What is pick-to-light?
Light modules at each pick location illuminate to show operators exactly where to pick and how many, confirmed at a button press. Related: put-to-light for consolidation, pack-to-light at pack stations, and voice-directed picking for hands-free work.
What is a checkweigh system?
An in-motion scale that weighs every package at line speed and automatically rejects any outside tolerance — catching missing items, underfills, and overfills. We integrate checkweighers, box openers, inline scales, manifest systems, and sortation.
Do you integrate WMS and TMS software?
Yes — advanced WMS and TMS systems automate inbound orders, inventory control, and outbound distribution using RF, barcode, and auto-ID, prioritizing and confirming activities against real-time conditions of space, equipment, inventory, and personnel.
Does Lone Star provide controls services in Houston?
Yes. We're headquartered in Houston, TX and provide electrical controls, PLC programming, and systems integration throughout Houston, the Gulf Coast, and all of Texas. Call 713-532-4444 to discuss your project.
Controls Engineering Across Texas
Lone Star Automated Systems is headquartered at 2500 Citywest Blvd., STE 150, Houston, TX 77042 and provides controls and PLC programming for manufacturers, distributors, and warehouse operations throughout the Gulf Coast and statewide.
Have a Controls Challenge?
New line, aging panel, or a WMS that doesn't talk to the floor — tell us what's not working and we'll scope the fix, from field devices to software.
713-532-4444