In today's manufacturing landscape, ageing automation systems are more than just outdated equipment, they represent growing operational risks. Legacy programmable logic controllers (PLCs), variable frequency drives (VFDs), and servo systems become increasingly difficult to maintain as spare parts become obsolete and unplanned downtime becomes more frequent. To remain competitive, manufacturers must modernise their automation infrastructure while ensuring production continuity.
Recognising these challenges, HoST partnered with a manufacturing customer to deliver a phased automation migration strategy that enhanced system reliability, improved operational performance, and laid the foundation for future scalability.
The Challenge:
- A manufacturing customer was operating multiple production lines with aging automation systems, including legacy VFDs, PLCs, and servo drives.
- As spare parts became harder to source and maintenance requirements increased, the customer faced:
- Higher risk of unplanned downtime
- Reduced operational efficiency
- Rising support complexity
The Solution:
- HoST developed a phased migration strategy to modernise critical automation components while minimising disruption to production.
- The project included:
- Upgrading legacy PowerFlex drives
- Migrating PLC systems to Allen-Bradley ControlLogix architecture
- Replacing obsolete servo drives and motors with integrated servo motion solutions.
Solution Migration:
HoST supported the customer across two key machine upgrade projects, covering multiple production assets and legacy Rockwell Automation systems.
Project 1: Pen Sinking Machine — 2 Machines
Function: Precision tube cutting
PowerFlex 755TS
Project 2: USG Machine — 5 Machines
Function: Cannula tip grinding
CompactLogix 5380 Controllers
PowerFlex 525
Kinetix 5500 Servo Drives
Kinetix VPL Low-inertia Servo Motors
Potential Migration
- 40 PowerFlex 700S to be migrated (Est. value US$100K)
- 90 Kinetix to be migrated (Est. value US$400K)
- 30 ControlLogix L6 to be migrated (Est. value US$600K)
The Implementation:
- Migration completed during scheduled shutdowns with minimal disruption to production.
- Existing control logic was successfully retained, reducing commissioning time.
- HoST delivered complete engineering support from planning through commissioning and operator training.
Results & Benefits:
- Following the upgrade, the customer achieved:
- Improved system reliability and reduced risk of unexpected downtime
- Enhanced machine performance and operational stability
- Increased availability of spare parts and long-term supportability
- Simplified maintenance and troubleshooting processes
- Improved production efficiency and equipment lifecycle management
Project Timeline
Assessment -> Planning -> Migration -> Testing -> Commissioning -> Training
Conclusion:
By modernising the customer's legacy automation system, HoST delivered a reliable, scalable platform that improves production performance while supporting future expansion and long-term maintainability.
Why HoST?
✔ Certified Rockwell Automation Solution Partner
✔ Complete project execution from assessment to commissioning
✔ Local engineering support in Singapore
✔ Long-term maintenance and lifecycle services
Download the Brochure Here
