Siemens Motion Control Powers Smart Car Wash Systems at Sergeant Sudz
Sergeant Sudz’s Recon IQ uses Siemens tech for improved energy savings, real-time alerts, and optimized motor control.
www.siemens.com
Sergeant Sudz, LLC, a builder of motor control cabinets and UL-508A Certified electrical panels, located in Greenville, Tennessee, made the INC 5000 list of fastest growing private companies in America in 2024 and owner James “JJ” Vanderwiele explains one of the key reasons. “We were developing our new Recon IQ unit to enable car wash operations to become more streamlined, energy efficient and capable of truly smart communication to the operator. We were seeking to create a unit that would be compatible with all standard conveyor equipment, including roller, surface and belt conveyors in the car wash, plus much more. The new unit needed to provide proactive notifications of any operational issues, via visual banners on a PLC, text messages, even email alerts.”
He further explains, “We wanted this new controller to seamlessly synchronize with conveyor speed, ensuring smooth operation as the vehicles progressed through the wash tunnel. With smart solenoid valves, chemical application, pumps and lights, our Recon IQ unit evaluates vehicle length and continuously monitors critical line signals for optimum performance and energy savings.”
Key to achieving this solution was the motion control system used. Previously, as Vanderwiele explained, Sergeant Sudz used an “old school serial dial-up” and conventional relay ladder logic that provided no alerts, only dedicated line signals to the HMI. All the previous supplier’s hardware and software had also increased substantially in price, so Vanderwiele went in search of a true partnership with another motion control supplier and found it in Siemens, through their distributor and IoT specialist elliTek, Inc. in Knoxville, Tennessee.
Through discussions with Brandon Ellis, president of elliTek and his team, as well as the Siemens OEM and Partner teams, led by Matt Wagner, Butch Martin and Andrew Miller, Vanderwiele decided on SINAMICS G120X drives and SIMATIC S7-1500 PLC with 15” Comfort Panel as the core Siemens products to achieve the desired solution. Energy-savings, water-savings and overall cost-savings have been realized, as Vanderwiele details.
“We were able to replace our previous vendor’s products with the SINAMICS drives and SIMATIC PLC controller, as a result of the thorough training my team received from Siemens and especially elliTek. In developing a network with full communications capability, we were able to gather more data with less product, plus provide our customers with a relatively easy-to-learn protocol for full car wash operations and predictive maintenance.” He further noted the old PC-based controllers were not as proficient as the Siemens PLC, both in terms of data gathering and especially remote alerts.
“To be honest, remote I/O was not well known in the car wash industry and we had some education to perform, but folks have quickly accepted the sense of it all. We’ve gone to CAT 5 cabling, DC relays for solenoids and other performance features not possible with the old 120V AC technology. This new system features inherent fault codes and provides resolution suggestion for immediate action, as needed. It simply makes the customer more self-sufficient,” Vanderwiele notes.
From a cost standpoint, the reduction of components and the use of “smart” drive technology have resulted in a documented savings on each motor in a system, based on cost per kilowatt-hour of power. The new Siemens solution can monitor each motor and operate it at a lower RPM. Along with the other cost-savings in water use and downtime maintenance, Vanderweile states the ROI on the Sergeant Sudz system is less than three years in operation. On a practical level for the car wash owner, having fewer stoppages and re-washes translates into immediate bottom-line improvements. Vanderwiele reports the typical customer currently saves 20% or more in operating costs from their use of the Sergeant Sudz systems.
Think of the drive system the way you would an auto-stop on your car. Traditionally, the motor in your car or your car wash would run constantly, including an idle speed. The new Sudz system allows a motor to run or not run, depending upon the function being performed in real time.
Brandon Ellis of elliTek observes, “We always enjoy working with innovative companies who change the industry. It’s both exciting and fun to work with JJ and his team, because they really do think outside the box, when it comes to product improvement that utilizes the most advanced yet affordable technology available.”
The smart control systems of Sergeant Sudz run the conveyor, brushes, spray devices, blowers, vacuum systems and tire dressing rollers in today’s automated car washes, plus they can control the safety/security systems and cameras, pay station portals, dryers and air lift door.
All the products currently produced by Sergeant Sudz are designed, engineered, built and tested at the company’s Greenville, Tennessee facility.
In June of 2025, Vontier Corporation (NYSE: VNT), a leading global provider of critical technologies and solutions to connect, manage and scale the mobility ecosystem, acquired Sergeant Sudz. The acquisition will combine Vontier’s existing DRB® car wash technology, including point-of-sale systems, digital consumer engagement, tunnel controls and data analysis, with Sergeant Sudz’ smart MCC and industrial automation expertise, giving tunnel car wash operators a comprehensive, digital solution to deliver greater productivity and efficiency.
www.siemens.com
