Hale Engineering & Consultancy Services
Hale engineering & consultancy services
Industrial automation, machine safety, control systems and OT cyber security engineering — across the UK
Industrial automation, machine safety, control systems and OT cyber security engineering — across the UK
automation, process and machine safety systems
PLC & control systems
Bespoke engineering solutions
Safety systems
When your automation fails, everything fails.
Hale Engineering keeps industrial sites running — safely, compliantly and without surprises.
We are a specialist industrial engineering company based in Kent, supporting sites across the UK with automation, PLC and control systems, machine safety, electrical compliance and long-term engineering partnership.
We are a Rockwell Automation partner and Cisco-aligned engineering company — backed by the technology that powers modern industry.
Trusted by industrial sites in:
Recycling and waste management
Energy and power generation
Logistics and distribution
Utilities and water treatment
Waste-to-energy
Manufacturing
Pharmaceuticals
Unplanned downtime costs UK manufacturers an average of £5,121 per hour.
Most of it is preventable.
The engineering problems industrial sites face are rarely mysterious. They are the predictable result of systems that have grown, changed and aged without structured oversight.
Does this sound familiar?
Your PLCs or SCADA systems are ageing — and increasingly difficult to support or fault-find
Machinery has been modified over time, but the safety systems have not kept pace
You have undocumented changes, inconsistent wiring and control panels no one fully understands
Compliance audits are uncomfortable because your documentation does not reflect reality
You know PUWER, COMAH or HSE obligations apply — but you are not confident you are meeting them
You are firefighting breakdowns instead of running a planned, reliable maintenance programme
Your control systems are connected to the business network, but nobody can say exactly how, or what could reach them
Remote access for OEMs and contractors was set up years ago and has never been reviewed
You have been asked by a customer, insurer or auditor to evidence your OT cyber posture — and you cannot
You have heard of the Cyber Security and Resilience Bill or NIS2 and are not sure whether they apply to your site
If two or more of those land, you are not alone — and you do not have to stay there.
Our flagship solution
Automation, process & machine safety reliability
This is what Hale Engineering is built around. Not a list of services — a single, integrated engineering discipline that addresses how industrial systems actually work: interconnected, interdependent and unforgiving when neglected.
We bring together:
PLC & control systems engineering
Programming, upgrades, fault-finding and legacy migration across Siemens, Allen-Bradley, Mitsubishi, Omron and other major platforms. As a Rockwell Automation partner, we have authorised access to Allen-Bradley technical resources and support that most firms simply do not.
SCADA & HMI development
Improving operator interfaces, alarm handling, data logging and trending — giving your team the visibility they need to run a site confidently, not reactively.
Machine safety & PUWER compliance
Safety system reviews, upgrades and documentation for machinery that has evolved faster than its safety circuits. We design and integrate safety relays, emergency stops, interlocks and light curtains that work in practice and hold up under HSE scrutiny.
Control panel design, build & upgrades
Bespoke panels and structured upgrades built around how your site actually operates — not generic specifications.
Process safety & safety instrumented systems (SIS)
HAZOP and FMEA-based hazard assessments, SIS specification, design and proof-testing in line with IEC 61511 and IEC 61508. For high-hazard environments, this is not optional — and we know how to do it properly.
Functional safety management
Full safety lifecycle management: risk assessment, safety requirements specification, design, validation, operation, maintenance and modification of safety instrumented systems.
Legacy system migration
Phased, risk-managed replacement of obsolete control hardware and software — reducing your exposure to unsupported platforms without disrupting production.
Remote diagnostics & technical support
Fast, secure remote access to diagnose and resolve issues without waiting for a site visit. When the problem is urgent, waiting is not an option.
Our third discipline
OT & industrial cyber security
Automation reliability and machine safety keep a site running. Cyber security now sits alongside them — because a compromised control system fails in exactly the same ways, and often faster.
The difficulty is that industrial cyber security is not IT security applied to a factory. Availability outranks confidentiality. You cannot patch on Tuesday. You cannot reboot the PLC to see what happens. Scanning tools designed for corporate networks can knock legacy controllers offline. The work needs engineers who understand both the threat and the process.
That is what we do.
OT asset discovery & network mapping
A complete inventory of controllers, HMIs, drives, network hardware and remote access paths, with firmware and software versions — passively gathered, with no disruption to running systems. The foundation for everything that follows.
OT security assessment
Structured review of your control system architecture, network segmentation, remote access, account management, backup regime and patch position, designed to IEC 62443 principles. Findings prioritised by operational consequence, with a costed, sequenced remediation plan.
Network segmentation & secure architecture
Designing and implementing the zones and conduits that separate enterprise IT from control systems, and control systems from each other — so a compromise on the business network cannot walk onto the plant floor. Delivered with Cisco industrial networking and Rockwell reference architectures.
Secure remote access
Controlled, auditable, time-limited access for your engineers, your OEMs and your contractors. Replacing the standing VPN, the shared password and the modem nobody has looked at since commissioning.
Control system backup, recovery & verified restore
Backups of PLC, HMI, SCADA and drive configurations that are current, retrievable and — critically — proven to restore. Most sites believe they have this. Few have tested it.
IT-layer security & Cyber Essentials support
Endpoint, identity, email and enterprise network security delivered by our specialist IT partner under Hale prime contract, along with support in achieving Cyber Essentials and Cyber Essentials Plus certification. One contract, one point of accountability, no gap between the IT provider and the control system.
Regulatory readiness — CSRB, NIS2 and CAF
Practical support for sites facing obligations under the UK Cyber Security and Resilience Bill, EU NIS2 or the NCSC Cyber Assessment Framework. We translate the requirement into an engineering plan, and produce evidence that stands up.
Incident readiness & response support
Preparing your team for the OT incident: response plan, recovery priorities, known-good configurations and escalation routes. Available as a retained service, with out-of-hours support remotely and on site.
Everything else your site needs — under one roof
Once automation and machine safety are stable, Hale Engineering supports the full engineering lifecycle of your site.
Electrical risk & compliance
EICR, PAT testing, thermal imaging surveys, emergency lighting certification and compliance consulting — keeping your site audit-ready and your electrical risk under control.
Maintenance & reliability
Planned preventative maintenance, reactive breakdown support, shutdown assistance and reliability reporting. Fewer surprises. Faster recovery when things do go wrong.
Electrical installation & site upgrades
Industrial electrical installations, machine relocations, drives, motors, variable speed systems, lighting upgrades and energy efficiency improvements as your site develops.
Engineering consultancy & future-proofing
Control system audits, obsolescence risk assessments, modernisation planning and technical advisory support. We help you make informed capital investment decisions — before a crisis forces your hand.
Why industrial sites choose Hale Engineering
Once automation, control and safety systems are stable and well-managed, Hale Engineering supports the broader engineering needs of your site as a single, accountable partner:
Engineer-led from day one
Every engagement begins with a qualified engineer — not a salesperson. We do not overspecify, upsell or rely on jargon. We understand how industrial sites actually operate under pressure.
Led by a proven specialist
Hale Engineering is led by Director Andy Hale, a specialist in Siemens, Allen-Bradley and Mitsubishi platforms with decades of hands-on industrial experience. You get a principal engineer who understands the detail — not a project manager who passes it on.
Rockwell Automation partner & Cisco-aligned
As an authorised Rockwell Automation partner, Hale Engineering has access to the full Allen-Bradley technology stack, technical support and product roadmap. Combined with Cisco-aligned industrial networking capability, we connect OT and IT infrastructure securely and reliably — the foundation of any modern industrial operation.
We own the IT/OT seam
Most sites end up with two suppliers who each stop at the firewall: an IT provider who will not touch the PLC, and a control systems firm who will not touch the network. The gap between them is precisely where industrial cyber risk sits. Hale Engineering takes that whole boundary under one contract — control systems, industrial networking and IT security — with our specialist IT partner delivering under our accountability, not alongside it.
Multi-disciplinary under one roof
Automation, control systems, machine safety, electrical compliance and maintenance — handled by one partner, with one point of accountability. No gap between suppliers. No finger-pointing when something goes wrong.
Experience in high-stakes environments
We are particularly experienced in recycling, waste-to-energy, manufacturing, utilities, energy, pharmaceuticals and logistics — environments where systems must perform reliably under pressure and where failure carries real operational, safety and regulatory consequences.
Security that respects production
We have spent decades keeping industrial plant running. That changes how we secure it: passive discovery over active scanning, segmentation phased around your shutdown windows, no change to a safety-related system without the engineering to back it. Cyber work that stops your line has failed, whatever the report says.
Technology partnerships
Hale Engineering works with the technology that powers modern industrial operations.
Rockwell Automation — Authorised Partner
Cisco — Industrial Networking
As an authorised Rockwell Automation partner, Hale Engineering has access to the full Allen-Bradley technology stack, technical support and product roadmap. Our Cisco industrial networking capability completes the picture — Rockwell and Cisco jointly define the converged plant-wide network architecture that modern secure industrial operations are built on. Segmentation, secure remote access and OT visibility are network problems before they are security problems, and we build them properly from the start.
UK-wide reach. Local approach.
We serve industrial clients across:
Wherever you’re based, we can deploy engineers quickly, with no compromise in quality.
Trusted by:
We don’t just work with industry leaders—we keep them running.
HALE Engineering provides electrical maintenance, control systems integration, custom panel builds, and safety systems for industrial clients across the UK. Whether you operate in manufacturing, water treatment, logistics, recycling, pharmaceuticals or energy—we’re the trusted engineering partner behind the scenes.
Client Testimonials
“We simply couldn’t have achieved our automotive manufacturing goals without the invaluable expertise of Hale Engineering. Their control systems and automation solutions have revolutionised our processes, enhancing efficiency, minimising downtime, and maximising productivity. Their tailored approach and unwavering support have made them an indispensable partner in our industry.”
“Hale Engineering has played a pivotal role in the success of our pharmaceutical facility. Their profound understanding of regulatory requirements and extensive experience in designing and implementing compliant automation systems have ensured our strict adherence to industry standards. With their unwavering commitment to quality, reliability, and meticulous documentation, they have significantly contributed to our manufacturing efficiency and regulatory compliance.”
“We wholeheartedly recommend Hale Engineering for their exceptional services in the food and beverage industry. Their mastery of control system design and seamless integration has enabled us to optimise our production lines, increase throughput, and maintain consistent product quality. Their unwavering dedication to food safety, hygiene, and regulatory compliance has made them an indispensable partner in our industry.”
Ready to stop reacting and start engineering with confidence?
Talk to a qualified engineer. Tell us what is going on on your site. We will give you a straight answer.
No obligation. No jargon. No salespeople.
+44 20 8154 6102
info@hale-eng.co.uk
Units 7 & 8 Riverside, Sir Thomas Longley Road, Medway City Estate, Rochester, Kent, ME2 4DP
Contact us:
Proudly partnered with:
+44 20 8154 6102
info@hale-eng.co.uk
Member of:
Contact us:
+44 20 8154 6102
info@hale-eng.co.uk
Proudly partnered with:
Member of: