Faulty Process Control? See How a PLC Upgrade Can Save You!
Your products are in demand. Your team is ready to go. But your process, powered by an aging PLC, can’t keep up. When it starts lagging, errors multiply, and productivity slows.
Outdated PLC systems disrupt production, resist integration with new technologies, and drain resources on never-ending maintenance. Clinging to obsolete technology is not a strategy. It’s a high-stakes gamble that sabotages efficiency.
Reliable process control is the bedrock of modern manufacturing. Moving in that direction should be in your 2025 manufacturing goals.
If you aren’t on page yet, reading this article will help.
We’ll uncover the signs of outdated PLC systems and explore the benefits of an industrial control system upgrade. You’ll also see how investing in a PLC upgrade pays off.
Signs of Outdated PLC Systems: How Do They Slow Down Production and Disrupt Process Control?
Can you imagine a car running the Indianapolis 500 race with an engine from the 1990s?
That’s how a legacy PLC fits into modern operations.
They glare red flags through slow response times, compatibility nightmares, and downtime.
At first, the issues start small.
A missed signal here. A late response there.
Then it escalates.
Poor data flow between legacy PLCs and automated systems delays process control actions. Compromised quality control due to inconsistent batch processing occurs. Shortly after, the production line halts. You scramble to fix glitches caused by an overburdened PLC.
Benefits of an Industrial Control System Upgrade
Upgrading your PLC can transform your operations in an instant.
The new and modern PLC system:
➔ Enhances process control.
➔ Integrates with other devices (robotics, IoT, etc.) in a seamless fashion.
➔ Delivers real-time process insights for supported decision-making.
We once had a client struggle with quality checks and compliance reporting. After an upgrade, they eliminated human error and ensured adherence to strict regulatory standards.
The benefits span across industries:
From boosting cycle times in automotive manufacturing to enabling precision in food production, modern PLCs unlock potential, reduce downtime, and elevate safety standards.
For today’s factories, a PLC upgrade is not about being ritzy or trendy. It’s an advantage for the business, felt strongest in your pockets and in employee morale.
The Quest from Legacy PLCs to Industry 4.0 Technology
Transitioning from legacy control systems to Industry 4.0 PLCs is a strategic move. As such, it requires careful planning and execution.
Look at this step-by-step roadmap to guide you through the process, ensuring minimal disruption and maximum benefits.
Fig. 1. PLC upgrade project stages.
The road may seem daunting, but with the right partner, it’s a smooth ride.
Verdusco Automation’s team can support you through installation to training, ensuring that your workforce embraces the change confidently.
ROI Breakdown: Investing in PLC Upgrades
Every investment deserves a measurable payoff.
Here’s how the benefits of PLC upgrades align across small, mid-sized, and large enterprises, along with real-world examples:
Fig. 2. Investment range, projected ROI, and example of real-case application related to a PLC upgrade and integration in the manufacturing facilities of different sizes.
While the initial investment in a PLC upgrade may seem significant, the long-term ROI is compelling.
To strengthen it further, let’s show you another way to measure potential gains.
If a legacy PLC system allows for 1000 units per day with a 5% error rate. The legacy output is:
● Legacy PLC System Output: 1000 units/day - 50 defective units = 950 good units/day
By contrast, an upgraded PLC system can boost efficiency by 15% and reduce the error rate to 1%, which means you can produce more “good” units per day:
● Upgraded PLC System Output: (1000 units/day * 1.15) - (1000 * 1.15 * 0.01) = 1150 units/day - 11.5 defective units = 1138.5 good units/day
Moving forward with a PLC upgrade represents a 19.8%.
By reducing downtime, improving efficiency, and enhancing process control, modern PLC systems deliver a competitive edge and drive substantial cost savings.
Conclusion
When you spend more time troubleshooting than innovating, it’s clear: your PLC is a roadblock, not a cornerstone.
Call your team and address the specific pain points your legacy PLC creates (poor process control and monitoring, waste, downtime, and inefficiencies).
Then, assess what a modern PLC can do for you.
See the real possibility to:
➔ Transform process control and monitoring and operations with unparalleled precision, scalability, and efficiency.
➔ Integrate other technologies (IoT, robotics, cloud connectivity, and AI-driven analytics).
➔ Gain peace of mind and a good night’s sleep, knowing your plant is reliable and secure.
Verdusco Automation is at the forefront of this revolution.
We specialize in:
➔ Customized PLC and robotic solutions for various manufacturing needs.
➔ Expert consultation & seamless integration.
➔ Long-term support & automation scalability.
Don’t let outdated systems hold you back. Contact Verdusco Automation today!
📩 Get in touch now: https://www.verduscoautomation.com/contact.
