Sterling Systems & Controls

What Sterling Systems & Controls does

Sterling Systems & Controls, Inc., founded in 1972 and headquartered in Sterling, Illinois, designs, engineers, manufactures, and commissions custom process automation systems for material weighing and ingredient batching. The company is a certified Allen-Bradley (Rockwell Automation) systems integrator building PLC-based control solutions on CompactLogix hardware with PanelView Plus HMIs, FactoryTalk visualization, .NET operator interfaces, and Microsoft SQL Server databases. Its proprietary software portfolio — WebCentral (browser-based supervisory control), PMPlanR (preventative maintenance planning), FreshStart (legacy upgrade migration), SandTrack, and ACCU-PORTION batching systems — extends its offering beyond pure equipment into data management, traceability, and continuous improvement tooling. The company operates an in-house UL/cUL-listed panel shop covering electrical, mechanical, structural, and software design under one roof.

Sterling serves industrial processors across multiple verticals: feed milling and pet food manufacturing (its primary vertical alongside baking and food processing), agriculture and grain handling, rubber compounding, specialty chemicals, frac sand, and adjacent industrial processing. Customer segments also include OEMs, system integrators, and contractors/engineering firms that embed Sterling controls into their equipment or plant projects. The company markets directly to enterprise buyers through technical Regional Sales Managers, with no distributors or reseller channels; quote requests are initiated via phone, website forms, or 'Request Quote' CTAs throughout the site.

Revenue is generated primarily through one-time custom-engineered equipment sales with turnkey delivery (design through commissioning), bundled software licensing (no annual software subscriptions), and optional professional services including on-site commissioning, operator training, preventative maintenance planning, and remote diagnostics. Post-sales 24/7 support is provided without requiring annual service contracts or upfront purchase orders, supporting multi-decade customer relationships such as Agri-King (30+ years) and Performix Nutrition Systems (25+ years). Sterling has been a subsidiary of the International Process Equipment Company (IPEC) family since 2014, alongside sister companies Prater Industries and Industrial Magnetics, Inc. As of 2024, the company is actively investing in facility expansion to scale production capacity for mechanical system stack-ups.

Name

Sterling Systems & Controls

Legal name

Sterling Systems & Controls, Inc.

Website

https://sterlingcontrols.com

Company type

Private

Founded year

1972

Operating status

Operating

Headcount range

11–50 employees

Short description

Sterling Systems & Controls designs and builds custom-engineered process automation systems — primarily ingredient batching, material weighing, and plantwide controls — for feed milling, pet food, baking, agriculture, rubber compounding, and industrial processors across the US and Canada.

Ownership category

akta.pro rank

Product category

Industrial Process Automation

NAICS

Food Product Machinery Manufacturing (333241), Instruments and Related Products Manufacturing for Measuring, Displaying, and Controlling Industrial Process Variables (334513), Other General Purpose Machinery Manufacturing (3339), Other Measuring and Controlling Device Manufacturing (334519)

SIC

General Industrial Machinery & Equipment (3560), Industrial Instruments For Measurement, Display, And Control (3823), Electrical Industrial Apparatus (3620)

akta.pro primary industry

Filling & Dosing Machines (Liquid/Powder/Solid) (IMAHAOAF)

akta.pro secondary industries

Process & Batch Control Software (Recipe Management, ISA-88) (IMAGABAH), Industrial Controllers & Control Systems (PLCs, PACs, CNC Controllers) (IMAHAHAH), Bagging, Pouching & Sachet Packaging Machines (IMALAOAJ), Conveying, Feeding & Accumulation Systems (Packaging Lines) (IMAHAOAK)

Keywords

• Process automation systems
• Batching and weighing
• Industrial process controls
• Bulk material handling
• PLC control systems

Headquarters

HQ city

Sterling

HQ country

United States

HQ region

North America

Offices1 record

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Personnel, Operations, Technology or R&D, Marketing or Sales, Infrastructure, Supply Chain

Revenue model

1. Custom-Engineered Process Equipment & Systems: Design, engineering, manufacturing, and commissioning of custom batching systems, weighing systems, process controls, bulk bag handling systems, liquid handling systems, and complete plantwide automation. Revenue is generated from one-time capital equipment sales with full turnkey delivery from design through startup support.
2. Software Licenses (WebCentral, PMPlanR, FreshStart): Proprietary software applications (WebCentral supervisory control, PMPlanR preventative maintenance, FreshStart legacy upgrades) are configured to the customer's process and integrated with hardware. No annual subscription fees for software; revenue model is bundled with equipment sale or standalone upgrade.
3. 24/7 After-Sales Support & Professional Services: 24/7 after-sales support provided without requiring annual service contracts or upfront PO. Support is delivered by the engineers who designed and built the system, ensuring continuity. Professional services include on-site commissioning, operator training, preventative maintenance planning, and remote diagnostics.

Go-to-market motion1 record

Distribution channels2 records

Marketing channels7 records

Core offering

Sterling Systems & Controls designs, engineers, manufactures, and commissions custom batching, weighing, and process automation systems for industrial feed, food, baking, rubber, and bulk solids processors. Each system combines custom mechanical equipment, in-house UL-listed control panels, Allen-Bradley PLC hardware, and proprietary .NET/SQL software (WebCentral, PMPlanR, FreshStart), delivered turnkey with 24/7 after-sales support.

Product overview

Sterling Systems & Controls is a custom-engineered process automation company offering integrated systems for material weighing, ingredient batching, process controls, and bulk material handling. Their portfolio centers on four core product areas: (1) Batching & Weighing Systems including automated micro/minor/major ingredient batching, material weighing, and semi-automatic hand prompt batching stations; (2) Controls & Automation featuring PLC-based systems using Allen-Bradley hardware with .NET operator interfaces and SQL databases, accompanied by proprietary software including WebCentral supervisory control, PMPlanR preventative maintenance, and FreshStart legacy upgrade tools; (3) Bulk Bag Handling Systems for filling and unloading FIBCs with capacities from 100-4400 lbs; and (4) Complete Process Systems providing turnkey plantwide automation for feed mills, food/baking, and industrial processing. The company operates a UL-listed panel shop providing electrical/mechanical engineering, software development, and 24/7 lifecycle support. Their systems integrate with Allen-Bradley PLCs, Rockwell FactoryTalk, Wonderware, and Intellution HMI platforms, with ERP integration via WebCentral. Key specialty systems include liquid handling, bearing condition monitoring, and rubber compounding batch controls. All products are custom-engineered to customer specifications rather than catalog-configured.

Differentiator

Problem solved

Functional benefit

Products and services

• Batching Systems Automated and semi-automatic ingredient batching systems for dry and liquid materials, including micro, minor, and bulk weighments. Features recipe management, lot tracking, and tolerance control for precise ingredient proportioning.
• Material Weighing Systems Precision material weighing systems combining load cell technology with automation for accurate measurement of dry bulk solids and liquids in industrial process applications.
• Micro Weighing Systems

Quantifiable outcome

• Precision batching accuracy for micro ingredients (typically under 50 lbs/23 kg) and minor ingredients (50–150 lbs/23–68 kg), verified by automated weighing and tolerance comparison within the batching control system.
• +3 more outcomes

Named customers7 records

Segments7 records

Ideal customer profiles4 records

Technology focussed Yes

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Integration8 records

Feature6 records

Partnerships

Four partnerships are on record, tiered core.

• Prater IndustriescoreStrategic or Co-development PartnerPrater Industries is a sister company under the IPEC (International Process Equipment Company) family alongside Sterling Systems & Controls and Industrial Magnetics. Prater manufactures particle size reduction equipment (hammermills, classifiers, fine grinders, lump breakers) and rotary airlock valves. Sterling and Prater collaborate to provide complete, integrated systems combining Prater's process equipment with Sterling's automation and controls. Sterling's bearing condition monitors are specifically designed for Prater brand mills and classifiers.
• Industrial Magnetics, Inc. (IMI)coreStrategic or Co-development PartnerIndustrial Magnetics, Inc. acquired both Sterling Systems & Controls and Prater Industries in 2014 and consolidated them under the IPEC (International Process Equipment Company) family. IMI is a leader in manufacturing permanent magnet and electromagnetic solutions for tramp metal removal. The three companies — Sterling, Prater, and IMI — are displayed together as members of the IPEC family on Sterling's website.
• Allen-Bradley (Rockwell Automation)coreTechnology or IntegrationSterling Systems & Controls is a certified Allen-Bradley systems integrator. The company routinely uses Allen-Bradley PLCs, PanelView Plus HMI touchscreens, and FactoryTalk ME/SE software platforms in its control systems. Rockwell Automation's CompactLogix PLC family and related I/O modules form the hardware backbone of Sterling's automation solutions. Sterling also uses .NET-based software integration with Rockwell ecosystems.
• Microsoft (.NET / SQL Server)coreTechnology or IntegrationSterling's PC-based automation systems and supervisory software applications are built using the Microsoft .NET framework and Microsoft SQL Server (or SQL Express) databases. WebCentral supervisory control software stores all batching, process, alarm, and historical data in SQL databases, enabling unlimited data capacity compared to PLC memory constraints.

Scale indicators5 records

Recent moves6 records

Expansion highlights5 records

Broad incumbents

• Bühler Group: Swiss global incumbent in feed milling, grain processing, and food processing equipment; much broader portfolio than Sterling, but its feed mill and bakery automation solutions overlap with Sterling's Feed Mill and Baking/Food verticals.
• Marel: Large-scale food processing automation provider with solutions across protein, dairy, and pet food — competes with Sterling in pet food and food processing batching/automation, though at a much larger scale.

Emerging players

• Piab: Provider of vacuum conveying, robotic gripping, and bulk material handling components for food and industrial processors; a partial competitor in bulk material handling adjacent to Sterling's bulk bag systems.

Direct peers

• Flexicon Corporation: Specializes in bulk bag filling/discharging, pneumatic conveying, and batching systems for food, feed, and industrial powders — overlapping directly with Sterling's bulk bag handling and bulk material batching lines.
• Schenck Process: Global supplier of weighing, feeding, screening, and air filtration solutions with deep presence in food, feed, and bulk solids — directly comparable to Sterling's batching/weighing and process control portfolio.
• Dynamic Air: Designer and manufacturer of pneumatic conveying and bulk material handling systems for food, feed, plastics, and chemicals — overlaps with Sterling's bulk bag and process automation business.
• Coperion (formerly Coperion K-Tron): Major supplier of feeding, weighing, and batching equipment for plastics, food, and chemicals; K-Tron feeder/batching line is highly comparable to Sterling's micro/minor/major weighment systems.
• AZO Group: German manufacturer of automated batching, dosing, and bulk material handling systems for food, feed, chemicals, and plastics — a close functional peer for Sterling's turnkey batching and plantwide automation.
• Hardy Process Solutions: Manufacturer of industrial weighing technology, load cells, and batching/control instrumentation — directly comparable to Sterling's weighing systems and PLC-integrated batching controls.
• Heat and Control: Manufacturer of processing, batching, and packaging equipment for snack food, prepared foods, and pet food — directly comparable to Sterling's food/baking automation and batching systems.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat5 records

Key risks6 records

Key highlights7 records

Customer concentration

• Xx.com/Sterling_SCI
• Facebookfacebook.com/SterlingSystemsAndControls

Compliance2 records

Revenue estimate

Valuation estimate

Number of profiles

Profiles1 record

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about Sterling Systems & Controls