Synergistic Solutions, Inc

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Many customers like to know about the company and people behind the products they buy. Here we will tell you a little about ourselves and our company.

Our Business Philosophy

We will achieve our purpose by applying controls technology in partnership with our customers. Synergy means the whole is greater than the sum of the parts. Our systems are an intrinsic part of the cement plant and the whole of our systems includes the process, the people, the controls technology and ourselves. We will develop and provide the training, systems and the technology necessary to deliver on our purpose. We will use the controls technology best suited to achieve our purpose. However, that technology must be proven, reliable, powerful and if possible, adhering to non-proprietary standards. We will work with controls manufacturers and will strive to install systems capable of a minimum 20 year life cycle. 

Process controls are the linking of man and process for the purpose of achieving the business goals of the enterprise. Our systems will include sensors, process and programmable logic controllers, strandard workstation components, personal computers, and final controlled devices. They will include superior connectivity, utilize standard and modular components wherever possible, will use industry standard programming and configuration techniques, as well as specialized ‘expert’ control techniques and software. Our systems will enhance the productivity of the cement plant.

Our Company

Our control experience includes the first preheater-precalciner kiln erected in the USA (Lehigh, Mason City IA), the design and development of the first programmable controller (PLC) large scale system applied in a cement plant (Modicon 384’s, 1976) and the first multi-loop microprocessor controllers with PLCs which was applied to a total cement plant/resource recovery operation (Micon/Modicon at Giant cement, 1980). We have developed specialized control strategies for most aspects of the cement plant operation, and have applied these strategies in plants throughout the USA.  We also developed personal computer software for permitting laboratory personnel to interface to raw mill process controllers and software for automatic acquisition of x-ray data and the integration of that information into laboratory data bases.

In 1978 Data Design Company was founded and incorporated in 1981. This was followed by the merger of Zystex Systems Technologies into Data Design Inc. The resulting company was renamed Synergy Systems Inc. The principals split the company into two components in 1987, which resulted in the formation of Synergistic Solutions, Inc.

Our Corporate Offices

Here is a picture of our corporate offices since 1988:

SSI Corporate Offices


A cement plant had an aging Distributed Controls System with integrated PLCs and sophisticated Process Controllers. The PLCs had been installed over time by several different suppliers. It was an objective to upgrade and consolidate PLCs while retaining a ‘standard’ installation approach which the plant was familiar with. Some portions of the plant PLCs and Process Controls deviated from the ‘standard’ control approach and were to be upgraded to the plant standard.


Retain and build on existing maintenance skills

Build on existing program methods which were well understood by maintenance personnel

Replace an aging and costly Distributed Control System

Salvage existing “standardized” PLC programs where possible, thereby reducing engineering cost

Mimic Operator interaction with existing Process Controls

Implement control improvements and retain features of replaced process controllers

Implement in a phased approach with no disturbance to production

Install when permitted by planned (or unplanned) plant process outages

To provide maximum equipment savings, SSI will specify equipment and Customer will purchase

Provide a new HMI design with emphasis on maintainability, reliability and interoperability

Provide an HMI design which would require absolute minimum operator training

Provide a system at a predetermined cost - no extras of any kind, no hidden or backend costs