Upgrading the Control Unit in a 25-Year-Old Filling Machine

A very well-performing filling machine needed an update of the control system as the original PLC and control panel had become extremely unreliable, affecting the stability and predictability of the filling process. At that point, the filling machine had been running for over 25 years, and the PLC had become obsolete.
Required Modifications:
  • Replace the old PLC with a new Allen-Bradley CompactLogix 5380 PLC.
  • Transfer all the logic to the new PLC using RSLogix and confirm a smooth transition.
  • Install a new 20” PanelView Plus 7 to integrate the majority of the original controls into the HMI function.
Results:

The upgrade of the filling machine’s control system was successfully completed, significantly enhancing its performance and reliability. The old PLC was replaced with a new Allen-Bradley CompactLogix 5380 PLC, which brought modern capabilities to the machine’s operations. All logic was transferred to the new PLC using RSLogix, and the transition was smooth, with no disruptions to the filling process.
Additionally, a new 20” PanelView Plus 7 was installed, integrating the majority of the original controls into the HMI function. This not only streamlined the machine’s operations but also improved user interaction, making it easier for operators to monitor and control the filling process. These upgrades have resulted in a marked improvement in the stability and predictability of the machine, ensuring that it can continue to perform at high levels for many more years

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