Solution

SOL-10

Lifecycle

Retrofit & Modernization

Replacing obsolete controls, drives and HMIs in planned shutdowns, without losing what the line already does well.

Solution

Lifecycle

Retrofit & Modernization

Replacing obsolete controls, drives and HMIs in planned shutdowns, without losing what the line already does well.

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Control architecture drawing of three packaging lines after PLC migration — FIG. 1
Illustrative application drawing · see the linked project record
SOL-10

Problem & outcome

What it solves

Problem & outcome

What it solves

The problem

A line can be mechanically sound and still be one failed CPU away from a long stop. Obsolete controls, unavailable spares and knowledge held by one person are risks that grow quietly until they don't.

The problem

Intended outcome

Supported controls, recovered documentation and a line that restarts at rate after each cutover.

Typical cutover

24–72 h per line

Indicative range · confirmed per project

Typical cutover

24–72 h per line

Indicative range · confirmed per project

Engineering

Approach, applications and scope

Engineering

Approach, applications and scope

Technical scope

Engineering approach

We start with an audit of hardware, software and documentation, then plan the migration in phases that fit your shutdown windows. New panels are pre-wired and the converted logic is tested in simulation before each cutover.

Typical applications

Legacy PLC, drive and HMI replacement
Safety reassessment after controls change
Documentation recovery
Phased line upgrades

Scope

Obsolescence audit and migration plan
Logic conversion and simulation testing
Pre-wired panels and cutover plan
Training and support handover

Technical scope

Engineering approach

Typical applications

Legacy PLC, drive and HMI replacement
Safety reassessment after controls change
Documentation recovery
Phased line upgrades

Scope

Obsolescence audit and migration plan
Logic conversion and simulation testing
Pre-wired panels and cutover plan
Training and support handover

Evidence

Project records

Evidence

Project records

PRJ-0239

Packaging & Consumer Goods

PLC & HMI modernization

Three lines moved from obsolete controls to a supported platform, each within a 48-hour window, with unplanned downtime down 41 %.

Unplanned downtime · h/month

Mean time to repair · min

Read project record →

Context

Industries and platforms

Context

Industries and platforms

Industries

IND-01

Automotive & Mobility

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IND-01

Automotive & Mobility

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IND-02

Food & Beverage

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IND-02

Food & Beverage

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IND-03

Packaging & Consumer Goods

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IND-03

Packaging & Consumer Goods

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IND-04

Metals & Fabrication

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IND-04

Metals & Fabrication

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IND-08

Machine Building & General Manufacturing

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IND-08

Machine Building & General Manufacturing

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Technology ecosystem

PLC / PAC

TEC-01

Siemens SIMATIC S7-1500 / TIA Portal

PLC and safety-PLC programming, TIA Portal migrations from legacy S7 and S5 platforms, PROFINET network design.

PROFINET · PROFIsafe · OPC UA

Experience

PLC / PAC

TEC-02

Rockwell Automation Allen-Bradley ControlLogix / CompactLogix

ControlLogix and CompactLogix control and safety programs, PLC-5 and SLC 500 migrations, FactoryTalk integration.

EtherNet/IP · CIP Safety

Experience

HMI / SCADA

TEC-12

Ignition by Inductive Automation

SCADA, HMI and production-data applications built on Ignition, including OEE and downtime reporting.

OPC UA · MQTT · SQL

Experience

Safety

TEC-14

SICK Safety Systems

Safety laser scanners, light curtains and safety controllers integrated into robot cells and material flow.

PROFIsafe · CIP Safety

Experience

Resources

Technical notes

Resources

Technical notes

Checklist

PLC migration readiness checklist

Retrofit & modernization

Checklist · 24 items

May 4, 2026

Read

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PLC migration readiness checklist

Retrofit & modernization

Read

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Technical Guide

Alarm rationalisation for operator HMIs

HMI & SCADA

Web guide · 7 min read

Jul 17, 2025

Read

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Alarm rationalisation for operator HMIs

HMI & SCADA

Read

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Talk to an engineer

Request a retrofit assessment

Start a Project Brief

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Use the Solution Finder

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An engineer replies within one business day.