Pilot to Production

Where Ideas Take Flight

PLC has helped several clients take novel concepts from early-stage ideas to fully functioning pilot systems and working prototypes. Whether the goal is technical validation, process optimization, or scale-up readiness, our team knows how to turn innovation into results. Our role is to bring structure, creativity, and discipline to that initial uncertainty so bold ideas can move from concept to proof.

Got a bold idea that’s stuck in neutral?

At PLC, we specialize in turning stalled concepts into scalable realities. Our Pilot to Production Service is designed for innovators who are ready to move from “what if” to “what’s next.” Whether your project is paused due to technical hurdles or needs a fresh approach to get off the ground, we bring the tools, talent, and tenacity to make it happen.

Year after year, clients trust PLC to breathe life into their pilot projects – and we deliver.

From concept to commissioning, we guide you through a proven process that transforms uncertainty into clarity, and prototypes into production-ready systems.

Why PLC Pilots Work

· Innovation meets execution. We don’t just dream – we build.

· Technology that works. We solve the problems others can’t.

· Results that matter. Every pilot is designed to deliver measurable success.

Process

Easy process. Only few steps

We define success before we design.

From day one, we work with our clients to understand exactly what success looks like. We establish measurable performance goals – product specifications, energy efficiency, throughput — and design every aspect of the pilot system to generate the data that matters most.

We balance innovation with practicality.

Pilot projects are about proving viability with minimal upfront capital. We focus investments where they have the greatest impact, delivering systems that meet technical objectives without unnecessary complexity or cost.

We design for discovery.

Unproven processes require flexibility. That’s why every pilot unit is built with adaptability-allowing operators to adjust temperatures, pressures, and recycle flows to explore alternate operating modes, accelerate learning, and uncover the most effective pathways forward.

Our recent Projects

Testimonials

from our clients

PLC delivered our gas processing facility on schedule and under budget, with engineering precision that exceeded our expectations.

James Mitchell

Their team understood our cryo facility requirements immediately and executed the design without compromise or delay.

Sarah Chen

From concept to startup, PLC managed every detail with the kind of attention that builds lasting partnerships.

Robert Valdez

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Ron Johnny

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Anna Avocado

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Jenny Joe

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Featured Case Study

Found Energy Corvo Project

Coordinated Automation & Controls for Aluminum Water Reactor Pilot

Executive Summary

Found Energy’s Corvo project is an aluminum water reactor pilot designed to generate hydrogen and thermal energy through a controlled reaction between aluminum and water. The project represents a research and development effort focused on validating core process concepts, system integration, and operability under real-world conditions. Found Energy led the development and iteration of the reactor process, mechanical systems, and test objectives, while PLC Construction served as a trusted engineering partner responsible for automation, controls, and electrical system execution. Working in close coordination, the teams translated system requirements into a flexible, test-ready control architecture that enabled safe operation, repeatable material handling, and scalability without extensive system rework.

The resulting pilot control system provided Found Energy with a stable platform for experimentation and validation, while intentionally preserving flexibility to support future process changes, subsystem additions, and scale-up exploration.

Client Testimonial

“The team at PLC was great to work with. They were able to get up to speed very quickly on our project and worked closely with us to deliver a very complex electrical and control system in record time. I have worked with numerous EPCs during my career and I have to say they are one of the best!” – Angie Ackroyd, VP of Engineering

Client:

Found Energy

Project Location:

Charlestown, MA

Industry:

Renewables/Municipal

Services:

Panel Fabrication, Engineering Services, Design Services, Automation/Control Systems, Commissioning, Field Services