Problem
A bottling line running on an obsolete PLC-5 platform was losing 40+ minutes a shift to unplanned faults, with no in-house engineer able to safely modify the logic.
Engineering Solution
Migrated control logic to Rockwell Studio 5000, rebuilt the HMI with rationalized alarms, and re-fabricated two UL 508A panels to correct thermal derating issues.
Measurable Outcome
Unplanned downtime cut from 40 minutes a shift to under 6. Line rate held at spec through three consecutive changeovers.
The client's bottling line had run on the same PLC-5 platform for over eighteen years. The original programmer had retired, spare processors were sourced from the secondhand market, and every unplanned fault meant a call to a contract programmer with a four-hour minimum response window.
We migrated the control logic function-by-function to Studio 5000, preserving every process behavior the operators already trusted while rebuilding the alarm hierarchy from the ground up. Two panels were re-fabricated to correct a thermal derating issue that had been silently shortening component life for years.
Facing a similar problem on your line? Scope it with an engineer — no obligation, no generic sales deck.
Request a Quote →