Project C

Machine Upgrade 2 – Full Control System Modernisation

Project Overview

For this project, the customer requested a complete upgrade of the machine’s control system. Several mechanical and electrical components were outdated, and the existing control structure could no longer support the machine’s performance requirements. Our goal was to deliver a modern, reliable, and fully integrated automation solution.

The Challenge

Ageing control system with limited functionality
Outdated magazine loaders, glue head, and pneumatic actuators
Gearboxes requiring replacement
No advanced motion control
Limited machine feedback and safety diagnostics .

The customer needed a fully upgraded system that improved reliability, enhanced control, and modernised the machine’s interface.

Our Solution

We carried out a complete redesign and installation of new control hardware, safety systems, motion control, and HMI technology, resulting in a modernized machine fit for current production demands.

1. Mechanical & Automation Upgrades

Magazine loaders replaced with new, efficient units
Existing glue head and pneumatic actuators removed and upgraded
Gearboxes replaced with high-precision servo motors
Vision system installed for enhanced product detection and quality checks

2. New PLC & Motion Control

All new hardware was fully controlled by a new PLC, configured using advanced motion control function blocks to synchronize mechanical movements and improve accuracy.

3. New HMI With Familiar Functionality

We installed a 9-inch touchscreen HMI, designed to mimic the look and functionality of the previous interface—giving operators a smooth transition while adding modern usability and improved diagnostics.

4. Safety System Upgrade

We completely rewired the machine’s safety devices:

All emergency stops and guard switches were connected to individual safety inputs
Each device now generates its own dedicated alarm, making troubleshooting faster
Integrated into a programmable safety controller for full system monitoring

5. Integration of Existing Machine Sections

Some machine sections remained mechanically unchanged, but we reconnected all necessary hardware to the new PLC and safety system for unified, dependable control.

6. New Electrical Designs & Documentation

The upgrade included: