Posted by Gerard Lynch on | Comments Off on Automated Tubular Backwash Filtration: A Smarter Approach to Industrial Water Management
Industrial facilities are under growing pressure to reduce water consumption, control wastewater costs, minimize maintenance, and improve process reliability. SIGMA Design Company’s Automated Tubular Backwash Filter Systems provide an engineered approach to these challenges by combining filtration, automation, solids concentration, and water recovery into one integrated solution.
Unlike traditional bag and cartridge filters that rely on disposable media, SIGMA’s tubular filtration systems automatically backwash to remove accumulated solids while maintaining the filtration process. The result is clean water that can be reused or returned to the process, along with a concentrated solids stream that can be directed to or integrated into existing solids-handling equipment.
SIGMA Design Company’s Automated Tubular Backwash Filter Systems provide continuous, automated filtration for demanding industrial water applications designed for process water, water reuse, cooling water, and solids concentration, the system removes suspended solids while reducing reliance on disposable filter media.
SIGMA’s systems can be customized to meet specific flow, filtration, footprint, and controls
requirements. Applications include cooling tower side stream filtration, heat exchanger and spray nozzle protection, food processing wash-water reuse, plastics recycling wash water, and pretreatment for membrane and DAF systems.
What sets SIGMA apart is our engineering-led, turnkey approach. Rather than simply supplying a filter, SIGMA can design and manufacture complete skid-mounted systems with PLC/HMI controls, multiple filter configurations, solids dewatering integration, and water recovery. With in-house engineering and manufacturing support, customers gain a single partner capable of designing, building, testing, and supporting the complete system.
SIGMA Automated Tubular Backwash Filter Systems provide an intelligent alternative between standard catalog filters and costly custom-engineered filtration projects— helping industrial facilities recover more water, manage solids more effectively, reduce consumables, and improve overall process efficiency.
Posted by Sarah Bunales on | Comments Off on Ag-Tech Innovation: Precision Nutrient Delivery for Indoor Farming
Customer: Large International Food & Beverage Supplier Industry: Food & Ag-Tech
Ag-Tech Innovation: Precision Nutrient Delivery for Indoor Farming
As controlled-environment agriculture continues to expand, reliable and precise nutrient delivery systems are critical to maximizing crop yield, consistency, and operational efficiency. Sigma Design partnered with a leading global food and beverage company to develop a custom nutrient injection and fluid handling system for a next-generation indoor hydroponic farming facility.
Leveraging decades of experience designing complex fluid handling systems across multiple industries, Sigma engineered a fully integrated nutrient dosing skid tailored to the customer’s facility requirements and operational goals. The system was designed to deliver precise nutrient concentrations while maintaining consistent water quality throughout the growing process.
Working closely with the customer, Sigma evaluated and optimized the proposed equipment architecture, selecting pumps and system components best suited for long-term performance, reliability, and maintainability. The resulting solution combined robust engineering, efficient packaging, and scalable design principles to support future growth in the rapidly evolving indoor agriculture sector.
From concept through fabrication and testing, Sigma provided a turnkey engineering solution that helped accelerate deployment while reducing technical risk.
Project Highlights
Custom nutrient injection and water dosing skid design
Fluid handling system engineering and optimization
Pump and component selection for demanding operating conditions
Integrated skid packaging to meet facility footprint constraints
Fabrication, assembly, and hydrostatic pressure testing
Design-for-reliability and long-term maintainability improvements
Sigma’s Impact
By combining deep fluid systems expertise with a collaborative engineering approach, Sigma delivered a precision nutrient delivery platform that supports efficient, data-driven indoor farming operations—helping our customer advance sustainable food production and agricultural innovation.
Services Performed:
Fluid Handling System Design • Nutrient Injection Skid Development • Component Selection & Optimization • Metal Fabrication • Hydrostatic Pressure Testing • Design Optimization
Posted by Sarah Bunales on | Comments Off on Equipment Loading and Transport Machine (Rotating Lift Cart)
Customer: Large manufacturer of decentralized power stations Industry: Energy
Equipment Loading and Transport Machine (Rotating Lift Cart)
Sigma designs and builds custom transport and loading/unloading machines for a large manufacturer of decentralized power stations
The “Rotating Lift Cart” designed by Sigma Design for a large manufacturer of decentralized power stations was created to assist fabricators and assembly technicians with moving their heavy test equipment from the final stages of the assembly line to the testing area, as well as assist with the loading and unloading of the equipment. The Rotating Lift Cart features an integrated scissor lift with a rotating table, allowing the equipment to be loaded from either side of the machine at heights from 12” to 30”.
The cart is driven using a Master Mover Electric Tugger via a custom coupling between the tiller and the cart. To help the operators load and unload the equipment, a DC Gearmotor-driven lead screw linear actuator is used to either pull or push the 800+ lb. equipment into or out of the testing enclosure. For the cart to be fully utilized when it is separated from the assembly line, a dual power solution was devised. When the cart is used on the assembly line, it can be powered from an AC drop at that station. When the cart is moving from station to station or moving away from the assembly line, the cart can be powered from the DC battery inside the Master Mover Tugger. This flexibility allows the scissor lift and actuator to always be functional, giving the operators more assistance in all parts of the factory.
Services Performed:
Concept development, testing protocol, controls, sensors, electronics, complete fabrication including all controls, machining, validation, and testing.
Posted by Sarah Bunales on | Comments Off on Mattress ASTM Testing Machines
Customer: SGS Govmark Industry: Industrial Testing and Certification
Mattress ASTM Testing Machines
Sigma designs two machines for SGS Govmark to evaluate mattresses to ASTM F1566-14 Specifications
The Durability Tester and the Cornell/Firmness tester are two standalone machines that were developed to test mattresses according to the procedures defined in the ASTM F1566-14 Specification.
The Durability Tester is used to test mattresses according to Section 7 of the specification and can test mattresses from twin size to queen size. The machine moves a 240 lb. roller back and forth across the mattress to simulate years of use. The roller is driven back and forth across the mattress via a servo driven belt system and once it starts it can run 100,000 cycle tests automatically without operator intervention or supervision. It features safety mat system to detect if any objects or person gets too close to the machine while operating and automatically stop all motion. The Cornell/Firmness Tester is used to test the mattresses according to Sections 6 & 9 of the specification.
The Cornell Tester uses a servo driven linear actuator with a two- lobe platen to continuously plunge into the mattress at 100 strokes per minute. A load cell mounted between the actuator and the platen is used to measure reactionary forces and determine how deep into the mattress to plunge. The machine then automatically stops at defined cycle counts and performs measurements on the reactionary forces of the mattress at set depths. Before and after a Durability Test or Cornell Test, a firmness test is run to determine the mattresses firmness in its “new & unused” state. The Firmness Test uses the same servo-driven linear actuator with a flat platen to plunge into the mattress at a rate of 10 inches per minute. The results during the test and changes between the before and after tests are then summarized in a table on the HMI as well as graphically for the operator and manufacturer to see the change in mattress properties over the duration of the test.
Services Performed:
Concept development, testing protocol, controls, sensors, electronics, complete fabrication including all controls, PLC/HMI, machining, validation, and testing.
Posted by Gerard Lynch on | Comments Off on Sigma Design Company’s New Industrial Water Systems
Industrial facilities today are demanding higher efficiency, tighter water quality control, and more reliable system uptime than ever before. For customer engineers in the water filtration sector, the pressure is clear: filtration performance must be smarter, more integrated, and more sustainable across the full process water lifecycle.
Water is the quiet workhorse of modern industry. It cools, cleans, transports, and transforms—but it also represents one of the biggest operational costs and sustainability challenges many manufacturers face today.
At Sigma Design, we’ve answered this demand with a new suite of industrial water system solutions purpose-built for filtration-intensive operations—from high-purity process water to closed-loop cooling and water reuse applications. This new platform focuses on modularity, energy efficiency, and advanced controls to help engineers deliver measurable value to their plants or clients.
Introducing Sigma Industrial Water Group’s Water Systems
At Sigma Design Company, our specialty lies in industrial water reuse and recovery, separation and filtration, desalination pretreatment, ultraviolet (UV) disinfection, and the reduction of wastewater TSS discharge. Our solutions can reduce or eliminate the labor needed for your existing water systems.
The Model 4614 UV + Automatic Prefilter Process Water System,which couples Sigma Industrial Water Group’s patented automatic water filtration technology with UV disinfection, a chemical-free water treatment process that uses ultraviolet (UV) light to kill or inactivate harmful microorganisms, including bacteria, viruses, and protozoa. It provides a highly effective, environmentally friendly, and easy to use solution for treating and disinfecting water in a wide range of applications and industries. Examples of applications include wastewater treatment and industrial water reuse and makeup water, while industries range from aquaculture to pharmaceutical production, electronics manufacturing, food & beverage, and other industrial markets.
What Are the Benefits of Turnkey Industrial Water Filtration Systems?
To reap the full benefits of your water filtration project, work with a one-stop engineering company like Sigma Design Company. With complete project management capabilities, our experts can help you develop a new system from scratch or integrate new components into an existing filtration system.
With a variety of past successful projects to draw from, Sigma Design can build all products to your unique specifications. Examples of turnkey systems we produce include:
Automatic Self-Cleaning Filters
Automation and Monitoring Systems
Disinfection Technologies
Water Reuse Equipment
Pumping Systems
Mixing and Dosing Systems
High Solids Separation
Microfiltration
Benefits to Customer Engineers in Filtration
Operational
More consistent inlet water conditions
Reduced fouling and scaling events
Longer media and membrane life
Reduced downtime for maintenance or CIP cycles
Energy & Cost Savings
Lower pump energy due to optimized hydraulics
Fewer chemical additions
Reduced cartridge or membrane changeout frequency
Lower wastewater treatment and discharge fees
Compliance & Reporting
Easier reporting for water quality, throughput, and lifecycle analysis
High-resolution tracking of SDI, turbidity, and conductivity
Improved regulatory readiness
Results:
40–60% reduction in RO fouling rate
25% drop in total CIP events
Stable SDI < 3 ahead of RO feed
Lower energy consumption per m³ permeate
What Sets A Sigma Design’s Water Systems Apart:
Multidisciplinary expertise – mechanical, process, electrical, controls, and thermal engineers under one roof
Prototype and test capabilities – the ability to pilot, test, and de-risk designs before full deployment
Vendor-neutral mindset – we select technologies and equipment based on what’s best for your process, not a single manufacturer
End-to-end ownership – from concept through commissioning and beyond, we stay involved
Why Work With Sigma Design Company for Industrial Water Filtration?
Sigma Design Company has served as a trusted partner of many top international brands since our inception in 1999. We’ve delivered over 1,000 successful design and design/build projects on time and within budget. Among our many areas of industry and equipment expertise, we have over 25 years of experience developing water filtration systems. We’re excited to release our latest line of industrial water filtration systems.
We’ve worked with the world’s largest water product manufacturers and recognize the need for custom industrial water solutions in the areas of TSS reduction, water disinfection, automated prefiltration, and control systems.
Sigma Design is a single-source, vertically integrated supplier offering UL 508A-certified industrial controls and ASME-certified welding.
Industrial Water Systems at Sigma Industrial Water Group
If you’re working to improve membrane longevity, stabilize feedwater quality, reduce energy and chemical consumption or push toward water reuse Sigma Design’s new industrial water systems are engineered to support these goals.
Schedule an assessment with us or learn more about how these systems can be fitted to your facility.
Send an email to info@sigmadesign.net or call us at 732.629.7555 or simply visit our website at www.sigmadesign.net.
Posted by RPM Developers on | Comments Off on What You Need to Know About Seawater Desalination Systems
Seawater desalination systems use reverse osmosis (RO) technology in tandem with other systems to effectively separate water molecules and remove various contaminants. In a seawater desalination system, high pressures force raw water through thousands of semipermeable, tightly wrapped membranes. Smaller molecules pass through these membranes, leaving salt and other impurities behind. This process helps to combat water scarcity, creating a reliable and sustainable filtration alternative for producing potable water.
Posted by RPM Developers on | Comments Off on The Role of UL 508A Certification in Industrial Control Design
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UL 508A certification plays a significant role in industrial control system design. This set of standards governs the construction of industrial control panels and is typically required by industrial equipment purchasers, insurance providers, and electrical inspectors.
At Sigma Design, these standards are foundational in helping us build safe, reliable control system designs. Below, we’ll discuss exactly what a UL 508A certification is and why it’s so important in industrial design.
What is UL 508A Certification?
UL 508A certification requires manufacturers to design, build, and test products according to preset standards before releasing them. Underwriter’s Laboratories (UL), an independent laboratory, collaborates with national and regional standards to develop and update these product safety standards. In the United States, UL is accredited by the American National Standards Institute (ANSI) as an official authority on product testing.
According to UL 508A requirements, the ambient temperature of control panels used in industrial settings cannot exceed 104 F unless otherwise specified. UL 508A also sets requirements for the product’s internal components, including:
Enclosures
Contactors
Interconnects
Motor drives
Overcurrent protection
Switches
Terminal blocks
Transformers
Construction projects must meet all written requirements to obtain their UL 508A certification, including printing electrical ratings and instructions directly onto control panels, to ensure safe installation and use.
Why is UL 508A Certification Important in Industrial Design?
Adhering to nationally recognized standards minimizes the risk of problems with product approvals, installation, and field usage. UL 508A certified panels are preferred by buyers and users alike due to the numerous benefits they offer, such as:
Reliable Protection. Ensures failed components will not catch on fire due to improper design or unlisted components.
Increased Productivity. Reduce unplanned downtime and liability claims due to equipment failures.
Peace of Mind. Buyers and users already know these devices adhere to rigorous safety standards.
Choosing a domestic UL 508A certified partner for your industrial design project ensures you receive well-tested, safe, and reliable products. Your chosen panel manufacturer should be knowledgeable on topics such as:
Current electrical wiring standards
Best practices for control panel layout
UL-certified enclosure fabrication
UL 508A label requirements
The Benefits of UL 508A Control Panels
UL 508A certification not only ensures that industrial control panels meet higher production standards, but it offers numerous other advantages as well:
Safety. UL 508A compliance ensures each control panel adheres to the highest possible safety standards. This reduces the risk of electrical hazards and safety concerns like fires.
Compliance. Certified products will adhere to major regulatory requirements, including general rules developed by the National Electric Code (NEC). Manufacturers should also factor in local building codes and standards to ensure panels are fully compliant.
Reliability. Our UL 508A certified products can be used with confidence, as they have been constructed entirely from high-quality materials. This significantly reduces the risk of equipment failure, thereby increasing operator safety.
Competitive Advantage. Exclusively using UL 508A certified control panels offers a distinct competitive advantage for manufacturers and allows them to demonstrate an ongoing commitment to safety and quality.
Insurability. UL 508A industrial control panels reduce the risk of losses and insurance claims. Using uncertified panels can void an owner’s insurance policy.
UL 508A Industrial Control Panels From Sigma Design
At Sigma Design, we take safety seriously. Our designs follow the UL 508A requirements for safe and reliable control systems, allowing our customers to experience products with long and productive service lives.
No matter how stringent your industry regulations are, we can design a solution that meets your needs. To learn more, contact our team today.
Posted by admin2 on | Comments Off on Reaching 25 Years is Worth Celebrating
Jerry Lynch was a young engineer working as the Manager of Engineering for Hayward Industrial Products in Elizabeth. His wife, Debbie Lynch was an associate professor at a local college where she ran a culinary program. They began looking for an entrepreneurial opportunity, ideally one that might merge their expertise in food + engineering. It almost happened on Long Island where they found a marina with a boatyard and a spot for a small restaurant. They continued to look for their shot at a ‘mom & pop’ while working their day jobs. They looked at other marinas, an industrial hoist company, and even a few restaurants.
In his role at Hayward, Jerry would occasionally outsource engineering design work to a business in Union founded in 1962 by three Lebanese American siblings, the original Sigma Design Company. One day a retirement conversation turned into an offer, and in 1999, the Lynch’s bought Sigma Design Company from the Abrahams, the founders.
This year we celebrate 25 years in business, a business that bears little resemblance to the first tiny office in Union NJ. In 1999, it was a drafting and design business that was unfortunately seeing more and more design work being sent overseas. Jerry knew that a pivot would be essential to staying in business, so Sigma added design/build to its offerings. Sigma quickly outgrew its second space in Springfield, even after adding a trailer behind the building. We began to look for a larger manufacturing space.
In October of 2011, Sigma Design Company purchased a 20,000 sq ft building in Middlesex, NJ, a leap of faith and a move made during an unseasonal snowfall. The offices up front were a messy warren of smelly, fake wood paneling, and clutter. The dark manufacturing space behind it was cavernous. It had been a former book binding printing company. With the help of CLS Project Solutions, (their first project was our new space!) the office space was renovated. Jerry’s vision for the manufacturing space was to create self-contained manufacturing work cells for new products. We needed well-equipped, safe workspaces for machining, welding, a UL panel shop and assembly. To make any of that happen, we needed to recruit, train, and retain the best technical employees possible. Sigma has been very fortunate to have assembled one of the most creative and skilled engineering and manufacturing teams in the business. On March 9th, 2024, the Sigma team and guests gathered at a dinner party to celebrate the 25th anniversary of Sigma Design Company. Cheers to the next 25!
Posted by Gerard Lynch on | Comments Off on Sigma Design Company: Celebrating 25 Years in Business!
One-stop Design, Engineering & Manufacturing
ASME & AWS Certified Welding
New Jersey-based, owned and operated, Sigma Design Company continues to be a dynamic and trusted manufacturing partner for businesses in the state and beyond. Not only are we focused on executing every client engagement seamlessly, on time, and budget; we are also intent on helping to expand manufacturing in New Jersey by leveraging our experience, knowledge, and customer-centric approach.
For 25 years, we have helped transform our clients’ ideas into highly effective product solutions. To date, we have delivered more than 1,000 successful design and design/build projects while saving our clients hundreds of thousands of dollars in manufacturing costs.
When President and CEO Gerard (Jerry) Lynch purchased the original Sigma Design Company in 1999, it was a small four-person machine design company. Within three years, the firm had evolved into a design-build shop, and just a year later, we were managing a number of projects for leading global companies as well as the US Navy.
Ag-Tech and Food Processing Equipment
We continue to build on that success. Every day, we strive to live up to our well-earned reputation as a trusted, one-stop, cost-effective resource for all aspects of product design and development, manufacturing, and validation, helping satisfy our clients’ business and revenue goals whether they are a start-up or major multinational brand.
Today, our global operations are located in a state-of-the-art 20,000 square foot Technology Commercialization and New Product Manufacturing Center in Middlesex, New Jersey, home to a complete manufacturing team plus advanced engineering services all under one roof.
UL508a Certified Electrical Enclosure and Panel Building
Our vast experience and expertise enables us to serve clients across a wide array of industries: ag-tech, food processing, clean energy & power generation; health & life sciences, water systems & filtration, culinary appliances and more.
As we celebrate our 25th anniversary, we remain committed to continuous improvement in all aspects of our operations, investing in the latest technologies and in our people with each team member a specialist in their field. We invite you to contact us to learn more about what sets us apart and how we can help you.
New Jersey-based Sigma Design is a leading one-stop design, engineering, and manufacturing resource for the development of specialty equipment and engineered systems. Our clients have included hundreds of leading global brands and manufacturing firms across a wide array of industries, transforming more than 1,000 design and design/build projects into successful products and specialty equipment in use across the world.
Posted by Gerard Lynch on | Comments Off on New Industrial Product Release Differential Pressure Alarm System
A New Differential Pressure Alarm System With Communications Module Model DPC-4570
DPC-4570 SPECIFICATIONS:
The new SIGMA DP Alarm Panel is ready to satisfy your Differential Pressure monitoring needs. The Differential Pressure (DP) Alarm Panel is a simple, easy to install and configure solution to monitor the pressure drop across a filtration media or other pressure sensitive processes. It is suitable for liquid and gas process systems.
Using our HMI Touch Screen, the user can easily:
Monitor inlet/outlet pressure on a continuously updating display with 0.1 PSI accuracy both locally and remote.
Dynamically adjust the DP alarm setpoint.
Monitor the current DP up to 20 PSID. A red LED stack light will turn on when the current DP pressure exceeds the setpoint value. The light can be configured to turn on solid or blink.
An optional audible alarm module can be added for non-visual indication. Additionally, a “dry” set of relay contacts will close (Ø1, 6A, 250 VAC). These contacts can be used to power ancillary equipment or remotely communicate with other industrial systems.
Why Monitoring Differential Pressure is Crucial in Process Applications:
Safety: Differential pressure measurement can also play a vital role in ensuring the safety of a process. By monitoring pressure differentials, operators can take immediate action to prevent accidents, equipment damage, and potential harm to personnel.
Efficiency: By monitoring differential pressure with the SIGMA DP Alarm Panel, you can assess the efficiency of the fluid process and identify potential issues such as blockages, leaks, or flow restrictions. This information can help optimize the process to ensure that it operates at its maximum efficiency.
Quality Control: In industries where precise control of fluid flow is essential for maintaining product quality, monitoring differential pressure becomes critical. Deviations in pressure can indicate changes in the composition, viscosity, or density of the fluid being processed, which can affect the quality of the end product. Regular monitoring with the SIGMA DP Alarm Panel allows for quick detection and correction of any issues that might compromise product quality.
Process Control: Many industrial processes require precise control of fluid flow rates to achieve desired outcomes. Using the SIGMA DP Alarm Panel, operators can adjust control valves and other equipment to maintain the desired pressure differentials, thus ensuring that the process operates within the specified parameters.
Equipment Health Monitoring: Changes in differential pressure can often signal equipment wear and tear or clogging. By regularly monitoring pressure differentials across filters, heat exchangers, and other components, maintenance teams can schedule preventive maintenance activities, reducing the likelihood of unexpected breakdowns and downtime.
Energy Efficiency: In systems where pumps and compressors are used to maintain fluid flow, monitoring differential pressure with the SIGMA DP Alarm Panel can help optimize energy consumption.
Regulatory Compliance: Is your industry subject to strict standards related to process conditions? Differential pressure measurement can provide documentation of compliance by demonstrating that pressure differentials are being maintained within specified ranges.
Troubleshooting: When an issue arises in a process, differential pressure measurement can provide valuable diagnostic information. The SIGMA DP Alarm Panel can detect sudden changes in pressure, which can help operators identify the location and nature of the problem, enabling faster troubleshooting and resolution.
Design and Manufacturing by Sigma Design Company
At Sigma Design Company, we recognize that monitoring differential pressure in process applications is essential for maintaining process efficiency, ensuring product quality, ensuring safety, controlling processes, monitoring equipment health, optimizing energy usage, complying with regulations, and troubleshooting issues. We have designed and manufactured the SIGMA DP Alarm Panel to provide critical insights that enable operators to make informed decisions and take timely actions to keep the process running smoothly and safely.
This year we celebrate 25 years in business, a business that bears little resemblance to the first tiny office in Union NJ. In 1999, it was a drafting and design business that was unfortunately seeing more and more design work being sent overseas. Jerry knew that a pivot would be essential to staying in business, so Sigma added design/build to its offerings. Sigma quickly outgrew its second space in Springfield, even after adding a trailer behind the building. We began to look for a larger manufacturing space.
