When changing a simple machine setting requires a formal risk assessment and a two-man job, the process is broken. This was the challenge facing the operations team at Quarry Mining‘s Heat Treatment Facility, and they turned to fellow HunterNet member ControlX for a solution.
Following ControlX’s recent announcement regarding the development of JasperNode, an AI-powered industrial automation platform, the two local companies partnered to pilot the technology on a critical production line.
The Challenge: Safety vs. Agility
At Quarry Mining’s facility, four critical machines (including quenching and temper furnaces) were operating on isolated legacy control systems. To adjust a simple power limit, the Facility Manager was required to open an electrical enclosure with exposed 415V connections.
“It wasn’t just inefficient; it was a safety hazard,” said Alex Sharikov, Director at ControlX. “Every time that cabinet opened, it triggered a requirement for risk assessments and spotters. We wanted to eliminate that risk without the expense of replacing the functional, heavy-duty machinery already in place.”
The Solution: An AI Bridge for Legacy Hardware
ControlX deployed JasperNode as a “digital bridge”, connecting the facility’s legacy S7-200 PLCs to a modern, secure interface.
Unlike traditional systems integration, which often requires weeks of custom coding, the control logic for this project was generated using JasperNode’s natural language processing capabilities. This allowed the team to deploy a solution rapidly that translates plain English requirements into the machine code necessary to develop the “bridge”.
Outcomes for the Hunter Region: The project has successfully moved into Stage 2, delivering immediate benefits to the Quarry Mining facility:
✅ Elimination of HV Risk: Operators now adjust setpoints via a central PC-based system. The 415V cabinets remain closed.
✅ Operational Visibility: A centralised dashboard now monitors alarms across all furnaces, removing the need for physical “walk-by” inspections.
✅ Business Continuity: The project included a full backup and digitisation of the legacy PLC code, protecting the site against hardware failure.
“This collaboration is a prime example of the HunterNet ecosystem at work,” said Sharikov. “We took a local manufacturing problem and solved it with local engineering innovation. We proved that you don’t need to rip and replace your factory to get the benefits of modern AI – you just need the right tools.”
ControlX continues to seek forward-thinking manufacturing partners within the Hunter region who are looking to modernise legacy equipment without the high cost of total replacement.
About ControlX
ControlX is a Newcastle-based industrial automation company and developer of JasperNode. They specialise in bridging the gap between legacy industrial hardware and modern software solutions.
Website: https://www.jasperx.com.au
About Quarry
Mining Quarry Mining is a leading manufacturer of high-quality drilling consumables and equipment, serving the mining and construction industries from its base in the Hunter Valley.
