Control System Modernization & PLC Migration
Replace Obsolete Controls Before They Fail
Is your critical equipment still running on a PLC from the 1980s, 1990s, or early 2000’s? Platforms like the Allen-Bradley PLC-5 and SLC 500 have been discontinued. Replacement parts are getting scarce, and when something fails, the repair options are limited.
PTS helps manufacturers in Cleveland and Northeast Ohio plan and execute a PLC migration with minimal disruptions.
Obsolete PLCs Put Production at Risk
Manufacturers typically phase out hardware 10 to 20 years after launch. Once a platform is discontinued, new parts and factory service go away. Your equipment may still run fine, but the support behind it is gone. A planned PLC migration turns an unpredictable emergency into a scheduled project with a known cost and timeline.
Spare Parts Are Hard to Find
When OEM parts dry up, the only source is third-party surplus sellers. Prices climb, quality is uncertain, and the part may not exist at all.
Service Options Are Limited
Fewer technicians know legacy platforms and software. A failure you can't fix in-house leaves you searching for help while production sits idle.
Failure Leads to Long Down Time
A failed processor or I/O card on an obsolete system can take days or weeks to resolve. That can easily exceed the cost of a planned upgrade.
PLC Migration Services
Allen-Bradley ControlLogix and CompactLogix are our preferred modern platforms, but we’ll work with whatever you have and whatever you want to move to.
Legacy Allen Bradley Systems to ControlLogix or CompactLogix
We migrate Allen Bradley PLC-5 or SLC 500 processors and I/O to a modern ControlLogix or CompactLogix system on Ethernet/IP. Your logic is rebuilt in Studio 5000 and tested before startup. Modernized PLC will be selected based on needs of the application and budget.
Other Platforms to Allen Bradley
Older Mitsubishi, Siemens, GE, or other controllers can be migrated to Allen-Bradley, or to a current version of your system.
Other Platform Modernizations
We can also modernize your Siemens, Mitsubishi, GE, Honeywell, ABB, or other control system to a current version of the same platform.
HMI and Operator Interface Upgrades
Outdated PanelView or other HMI terminals replaced with modern HMIs, so graphics and logic go live together.
Existing System Assessment
We review your current system, identify obsolete components, and recommend a migration plan and budget.
Why Choose PTS for Your PLC Migration
We Work With Your Equipment
We have experience working with all major PLC and HMI systems.
Integrator Hardware Pricing
Our supplier relationships often allow us to beat end-user pricing.
Local to Northeast Ohio
Based in Cleveland, we are close enough to support startup on site, while also servicing clients nationwide.
Cost-Competitve Rates
Hourly rates are lower than many larger and national controls integrators.
HMI and PLC Platform Programming Experience
Our HMI and PLC programmers have programmed most types of PLC processors and HMI types, and if we haven’t, we will figure it out quickly. Some of the PLC and HMI platforms we have experience with are:
- Allen Bradley
- Honeywell
- GE / Emerson Fanuc
- Siemens
- Automation Direct
- Maple
- Beijer
- Proface
See Our Control System Modernization Projects
PTS Project Managers and Engineers have successfully completed and specialize in control system modernization projects for the Metal Processing, Food & Beverage, Chemical & Process, and General Manufacturing industries. Check out a sample of some of our previous projects.
Ring Mill Controls Modernization
A 30-year-old PLC-5 system with DC drives, migrated to ControlLogix with new drives and enclosures.
Forge Furnace Modernizations
Seven furnaces upgraded with new control enclosures.
Forge Furnace Automation & SCADA
Furnace controls automation with SCADA monitoring.
Ready to Start Your PLC Migration Project?
Other Automation Services
From one piece of the project to design-build, we perform a variety of automation services to help you increase productivity, improve safety, and boost profitability.
PLC & HMI Programming
SCADA
