Replace aging PLCs, panels, HMIs and SCADA in place
Controls Retrofit Services
A controls retrofit replaces the control hardware and software on a machine that is still in use. We document the existing machine first, then test the new controls before cutover.
What a retrofit includes
- Document the existing machine before changing anything
- Replace PLCs, HMIs, panels, drives and SCADA screens as needed
- Test the new program before the cutover day
- Plan cutover around your shutdowns and production schedule
- Run a safety review during commissioning
- Provide on-site and remote support after startup
Why CtrlSystems
- Certified Ignition Gold Integrator; all client SCADA runs on Ignition
- Mostly Allen-Bradley PLCs, including PLC-5 and SLC 500
- Undocumented machines are documented before we change them
Related Projects
Sustainable consumer products
Packaging Line Optimization – Tru Earth
A stable packaging line and a trained team to run it.
Food manufacturing & packaging
Packaging Machine Recovery – Canbrands Specialty Foods
The machine is back in reliable operation with minimal downtime.
Battery recycling (smelting plant)
Control System Modernization – Terrapure Environmental
Modern controls, better monitoring and ongoing support for a critical operation.
Common Questions
When should we retrofit instead of replacing the machine?
Retrofit when the mechanical base is sound and the controls are the problem. Keep frames, drives and actuators that still work. A full replacement is the better option if the machine cannot meet current process or safety needs.
Can you retrofit a machine with no documentation?
Yes. We document the existing machine before changing it. That record becomes the baseline for the new controls and for future changes.
Will the machine be down for the whole retrofit?
Usually not. Programming and testing happen before the cutover. The cutover is scheduled around your shutdowns and production plan.
Request a quote for your controls retrofit.