Challenge

When is the best time to upgrade a decades-trusted PLC system? This was the challenge for a global supplier of spice ingredients. Their Allen Bradley PLC-5 system was commissioned over 25 years ago and, while it performed well for many years, the outdated platform began experiencing constraints. The obsolete equipment was limiting network connections. This urged the global spice supplier to seek a system integrator that could provide timely PLC migration support using the latest technology available. E Tech Group was recruited to modernize their obsolete PLC system to a more IIOT friendly platform.

Solution

The first step was reverse engineering the customer’s legacy system and well-documenting its current design to address potential risks and how to best program the new system. E Tech Group analyzed existing diagrams and worked extensively with the customer’s personnel to further detail device and wiring configurations. This step was crucial to improve system performance and have an accurate picture of their control environment before moving to the design phase.   

As a leading Rockwell Automation system integrator, E Tech Group developed a simplified migration plan leveraging the latest Rockwell Automation technologies. The global spice supplier’s legacy Allen Bradley PLC-5 system was upgraded to the ControlLogix platform. An L82E processor was utilized and the old RIO and DH+ networks were changed to Ethernet/IP network communications. Outdated Allen Bradley 1336 variable frequency drives were also upgraded to Powerflex 525 variable frequency drives, offering a wide range of motor control. Additionally, the customer’s FactoryTalk View SE screens were updated and consolidated which made the system easier to understand and operate by plant personnel.

Results

The project was successfully executed to schedule. The global spice supplier’s focus was continue their journey to digital transformation and the PLC-5 to ControlLogix migration accomplished this goal, supporting improved performance, greater uptime, and a more user-friendly interface. E Tech Group staffed the project with four subject matter experts to provide comprehensive multidisciplinary engineering support in PLC programming, FTView SE application programming and networking, as well as drafting and design. The project team successfully upgraded the customer’s PLC system with trusted projected performance for decades to come.