The Project: Remove Production Constraints with Complete Control System Upgrade

A global supplier of spice ingredients needed to upgrade their 25-year-old Allen Bradley PLC-5 system. The outdated platform was experiencing constraints and was limiting network connections. The client was seeking a system integrator that could provide timely PLC migration support using the latest technology available.

Automation Group, an E Tech Group Company was recruited to modernize their obsolete PLC system to a more IIOT-friendly platform. Automation Group, E Tech Group’s most recent acquisition, is a leading provider of automation services. They’ve worked with over 1000 clients across North America, implementing advanced control system solutions tailored to each facility’s unique challenges.

The Solution: Implement an Integrated, IIoT-Compatible Control System

E Tech Group automation professionals reverse-engineered the customer’s legacy system and analyzed existing diagrams to identify potential risks to obtain detailed information on device and wiring configurations. This step was crucial to improve control system performance and understand their control environment before moving to the design phase.

As a leading Rockwell Automation system integrator and CSIA-certified automation company, we developed a simplified migration plan using the latest technologies. We converted all networks to Ethernet/IP communications, upgraded the client’s PLC-5 system to ControlLogix and consolidated FactoryTalk View SE screens, making it easier for plant personnel to operate the system.

The Results: The First Step in a Digital Transformation

The global spice supplier’s upgrade from PLC-5 to ControlLogix was completed on schedule and improved performance, greater uptime, and a more user-friendly interface for the client’s PLC system. This upgrade project was a crucial step in the client’s digital transformation journey.

Our recent addition, Automation Group, an E Tech Group Company, designed and implemented this creative automation system solution. For more information on this control system upgrade, visit their website to read the complete case study.