In today’s industry, the reliability and efficiency of control systems play a key role. Many plants still use solutions from a dozen or even several dozen years ago. Although they still work correctly, their operation is becoming increasingly difficult due to the lack of manufacturer support and limited availability of spare parts.

Modernization of control systems is therefore an inevitable step towards increasing efficiency and adapting the plant to modern standards. Depending on the needs and technical conditions, it can be carried out in several ways.

1. Complete replacement of the control system

The most comprehensive solution is a full modernization, including the replacement of the entire control infrastructure, including control cabinets, cabling and PLC controllers. This approach ensures the implementation of the latest technologies and full adaptation of the system to the requirements of Industry 4.0.

How is a complete modernization carried out?

✔ One-time replacement of the entire system

This is the most demanding method, because it requires stopping production for a longer period of time. During this time, old systems are dismantled, new components are installed and the entire control system is launched from scratch. After the modernization is completed, the plant operates as if it were a newly built factory.

✔ Gradual modernization without long downtimes

In this case, the replacement takes place in stages, during short production stoppages. Each break allows for the successive replacement of individual control cabinets and control modules. In order to ensure continuity of work, additional solutions are used, e.g. indirect control by a new PLC, which “cheat” the previous system, allowing it to continue to function until full migration.

2. Replacement of communication modules and industrial networks

In many cases, the customer has a working control system, but based on outdated technologies that are no longer supported by manufacturers. In such a scenario, the problem is the availability of spare parts – any failure can mean a long downtime and the need for expensive replacement of damaged components.

What does the modernization of communication modules look like?

This process involves replacing key control elements, such as:

🔹 PLC controllers – newer models provide greater computing power, extended functionality, and support for modern communication protocols.

🔹 Communication modules – enable integration with modern systems, including Profinet, EtherCAT, Modbus TCP networks, etc.

🔹 I/O island interfaces or entire islands – enable more efficient I/O support and improve communication between devices in the plant.

Often, this type of modernization can be carried out in stages to minimize disruptions to production. This allows the system to be gradually adapted to new solutions without having to replace it completely.

3. Control software modernization

Migrating to modern control systems is a challenge, but at the same time an investment in the future of the plant. New technologies, such as advanced PLC, IoT and SCADA controllers, allow for:

🔹 Preparation of a parallel control system – a new set of PLC, SCADA controllers and dedicated applications are implemented, which enable smooth migration.

🔹 Integration with existing modules – components compatible with older equipment are selected, which allows for its further use.

🔹 Testing and gradual implementation – the new system operates in parallel, and changes are introduced step by step, limiting interference in the current operation of the plant to a minimum.

The only physical modification is reconnecting the communication cables to the new system, which makes this method the least invasive and at the same time the most cost-effective when we want to preserve the existing infrastructure.