When a critical piece of machinery breaks down and the original manufacturer no longer supports it, businesses are often faced with a difficult choice: purchase an entirely new machine or find a way to safely upgrade the existing equipment. At ST&L, we specialise in providing cost-effective, compliant solutions that get your production lines moving again without compromising on safety or efficiency.
Why the Client Contacted ST&L
The client’s plastic bottle blow-moulding machine had been out of production for six months. This costly downtime was caused by the failure of the existing PLC control system, which was obsolete and no longer supported by the original machine manufacturer. While the manufacturer had offered an expensive bespoke control system, the client sought a more practical and reliable alternative.
Often, with machines over 20 years old, the original manufacturer either no longer exists or has stopped supporting those models. Consequently, facilities are told their only option is to purchase a brand-new machine, even though the mechanical function of the existing equipment remains in perfect working order. The client contacted ST&L to return the machine to full operational condition by replacing the obsolete system with a state-of-the-art Siemens PLC.
Key Benefits of the Upgrade
Upgrading legacy machinery rather than replacing it offers several distinct advantages for your facility:
- Significant Cost Savings: By upgrading the control system rather than scrapping the mechanical hardware, the client avoided a massive capital expenditure.
- Enhanced Reliability: The installation of a modern Siemens PLC ensures long-term operational stability and minimises the risk of future downtime.
- Regulatory Compliance: Integrating new control systems ensures the machinery meets current safety regulations. Our upgrades align seamlessly with our comprehensive CE marking services, guaranteeing full legal compliance and worker safety.
Project Objectives
To ensure a seamless transition and minimal disruption to the facility, our team focused on the following objectives:
- Implement a structured strategy to manage the feasibility of the PLC replacement.
- Liaise closely with the client’s operators and production staff to design and develop a solution that minimised impact on existing processes.
- Design and manage the safe installation of the new PLC control system.
- Write, test, and commission the new PLC software to ensure flawless operation.
ST&L Scope of Works
ST&L undertook a comprehensive suite of activities to resolve the technical uncertainties and deliver a robust, upgraded system:
- Conducted an initial feasibility study.
- Investigated the existing control systems and architecture.
- Executed detailed systems design work.
- Developed individual system components tailored to the machine.
- Integrated system components to create a working prototype.
- Tested the prototype system rigorously under simulated conditions.
- Integrated the new control technology with the existing manufacturing hardware.
- Performed extensive testing of the integrated technology on the factory floor.
- Re-developed and refined the system to resolve any issues encountered during testing.
- Completed final commissioning and handover to the client.
Expert Training and Ongoing Support
Worker safety and operational efficiency must be guaranteed over the long term. Alongside our engineering solutions, we offer a range of dedicated training courses to ensure your staff is fully equipped to operate, manage, and maintain newly upgraded systems safely.
Meeting the huge range of legal safety requirements while ensuring your facility remains productive and profitable is a delicate balancing act. Whether you are dealing with obsolete machinery or looking to ensure your established equipment remains fully compliant, ST&L has the expertise to share the responsibility of maintaining a safe workplace.
