Location: Citrusdal, Western Cape, South Africa
Client: XSIT (Pty) Ltd – Citrusdal facility
Scope: Re‑wiring and refurbishment of control system board and associated extruder system.

Background & Challenge

At the XSIT facility in Citrusdal, the processing line for critical biological‑insect control operations required a major upgrade. The control system board had become outdated, wiring was ageing, and the extruder system that supports production needed enhanced reliability, improved safety and upgraded automation to meet operational demands. Given the facility’s key role in industry‑scale operations, downtime and performance issues were not acceptable.

Our Solution

WJ Cotter Electrical took on the project to refurbish the control system board and to work on the extruder’s electrical infrastructure. Key elements included:

• Complete re‑wiring of the control system board: removing legacy cabling, installing new wiring to modern standards, improving layout and accessibility.
• Refurbishment and upgrade of the control board: component replacement, improved thermal management, labelling and documentation for clarity and maintenance ease.
• Extruder system electrical upgrade: integration of improved motor controls, updated safety interlocks, refined control logic and enhanced operator interface to increase process reliability.
• Compliance and safety assurance: all work carried out in accordance with South African electrical standards (insert certification numbers when available), ensuring the system is safe, auditable and maintainable.
• Commissioning and handover: full functional testing, operator training and documentation provided to ensure smooth transition to production mode with minimal disruption.

Key Outcomes

• Significantly improved reliability of the extruder line — fewer unplanned stoppages and improved uptime.
• Enhanced clarity and simplicity of the control board layout, making future maintenance faster and more efficient.
• Improved compliance and safety of the installation, demonstrating WJ Cotter Electrical’s commitment to transparency, integrity and accountability.
• Localised, on‑site support in the Western Cape region ensured minimal interruption and efficient project delivery.

Why This Project Matters

This refurbishment at the XSIT Citrusdal facility underscores the importance of reliable electrical and control systems in high‑stakes operational environments. By bringing modernisation, safety standards and technical excellence together, the project reinforces WJ Cotter Electrical’s role as a trusted partner for industrial‑control upgrades across South Africa.

Interested in Upgrading Your Control Systems?

If your facility is facing ageing control boards, unreliable machine systems or requires a full electrical upgrade with compliance assurance, WJ Cotter Electrical is ready to assist.
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