Machine & Plant Upgrades

Updates to Existing Systems and Machinery
PLC, HMI & SCADA system upgrades, retrieve existing programs from obsolete systems.
Improvements to old machinery, speed & efficiency improvements, reduce downtime
Electrical & Mechanical upgrades, Control Panel Replacements, Upgrade Relay Logic to PLC
Safety Upgrades: Safety Controllers & Relays, Machine Guarding


For More information or a Quote

Contact Us or call (02) 9627 9011

Atlanta Stretch Pallet Wrapping Machine Upgrade

Pallet Stretch Wrapping Machine Upgrade

  • Replaced existing Allen Bradley Micrologix 1400 with PointIO
  • Replaced Safety Relay With PointIO Safety Modules & Coding
  • Changed Drives from Omron to Powerflex 525, with Ethernet Control
  • Code integrated into Palletising Line
  • Alarms & Faults Integrated into Plant Network


Dual Glycerin IBC Stand Replacement

  • The IBC stand is capable of holding 2 full IBC's at the same time.
  • The IBC's are connected together by pipe work & pneumatic valves
  • The IBC frames will be able to be tilted so the material waste will be minimised.
  • Replaced existing IBC Stand & Control
  • Allen Bradley PointIO & Powerflex 525 for Pump Control & Integration into plant PLC
  • New pneumatic cylinders & Level Sensors
  • The system will automatically change IBC's when finished
  • Siren & Indicator to notify the operator that an IBC is empty

Kliklok Concorde K100R Upgrade

Box End Load Cartoning Machine Upgrade & Control Improvements

  • Replaced existing Siemens S5-95U & COROS OP5 HMI with Allen Bradley Micrologix 1400 and Red lion HMI
  • Larger HMI, More Machine Information & Diagnostics
  • Updated Alarm System
  • Speed & Machine Adjustment Improvements and Reduce Complexity
  • Better Integration with existing line for reduced downtime and faults
  • Integrated with new flap detection system

Mill & Oven Safety Upgrade

A Food Processing line with a basic safety system required an upgrade to comply with site safety standards.

  • Allen Bradley GuardLogix Safety PLC
  • Allen Bradley PointIO Safety Modules
  • Ethernet/IP Communications
  • Ladder Logix Safety Programming (RSLogix 5000)
  • Guard Magnetic Guard Switches & Lockable Guard Switches
  • Banner Emergency Stops With Local Status Illumination
  • Upgrade safety on Grain Mill
  • Guard Switching with Maintenance Jog Function on Sheeter Machine Doors
  • Banner Emergency Stops With Local Status Illumination
  • Oven Door Fortress Lock System and Maintenance Jog Feature
  • .

Sprinter Carton Forming Machine Upgrade

Replace existing relay logic and DOL Control for integration into plant system and safety

  • New Enclosure with AB PointIO, Safety & Standard Modules
  • New Powerflex 525 Drives, for speed control based on product selection
  • Full integration with downstream line
  • Speed Control, Faults & Diagnostics now available at Line HMI

M80 Injection Molding Machine

Plastic Molding machine running a DOS based Proprietary program to control cycle times and machine control via pushbutton and switches

  • Replaced existing Koyo PLC, with GE VersaMax PLC
  • GE QuickPanel IC754 HMI
  • New recipe system with HMI Selection and allows for multiple product recipes
  • Main and secondary axis speed adjustments & checks
  • Manual & automatic system Control
  • Documentation: Operator manual, Maintenance guide, spare parts list, electrical drawings & Factory Acceptance Tests

Laminating Line Guarding & Safety

A 30 year old line with minimal safety required the upgrade of its safety system. The Line consisted of a Rolling Press, Hot Glue Area, Conveyors, Product Flipping Machines, Saw Booths and Palletiser

  • Allen Bradley SmartGuard 600 Safety PLC
  • Guard I/O Modules
  • DeviceNET Communications
  • Function Block Programming of Safety Functions (RSNetworks DNET)
  • Installation of Guard doors, Replacement of old emergency stop buttons, Install and wire guard switch's, Light Curtain for Palletiser
  • Integration with existing line control with staged stopping of machinery
  • .

Viking Machine Upgrade

Upgrade of a Viking Turbo Pallet Making Machine

  • Replace Exiting Relay Logic, Enclosure, Push Button Control
  • New Enclosure, Allen Bradley PLC & Panelview HMI
  • Rewire Field Equipment, Sensors, Limit Switches
  • Repair Existing Vibration Control Panel
  • Complete Documentation

Roll forming Machine Upgrade

Roll forming Machine upgrade

  • Use Existing Power Hardware
  • Interface with New PLC Control Box and HMI
  • Allow for recipe, Automated Control
  • Accurate Multiple Cuts without user intervention
  • Encoder added for length calculations