When should a control system be upgraded rather than replaced?

A control system should be upgraded when the mechanical equipment remains serviceable but automation components such as PLCs, SCADA, or panels are obsolete, unsupported, or unreliable.

Can control system upgrades be completed without stopping production?

In many cases, yes. Phased upgrades, parallel systems, and planned changeovers allow production to continue while upgrades are implemented safely.

What risks are associated with full system replacement?

Full system replacement can introduce higher downtime, operational risk, and cost. A structured upgrade approach reduces these risks while improving reliability.

Do you work with legacy PLC and SCADA systems?

Yes. We have extensive experience upgrading and migrating legacy PLC and SCADA systems to modern platforms while maintaining existing functionality where possible.

How does documentation improve long-term system support?

Clear documentation allows engineers to fault find, modify, and maintain systems safely, reducing dependency on specific individuals and lowering long-term operational risk.

Which platforms do you support for upgrades and refurbishment?

We support Siemens, Allen Bradley, and Mitsubishi platforms, as well as a wide range of legacy and specialist systems.

Control System Upgrades & Refurbishment

Modernise Automation Systems Without Unnecessary Risk

Stratos Control Systems delivers planned control system upgrades and refurbishment services that reduce downtime, improve reliability, and extend the life of existing industrial assets.

When PLCs, SCADA systems, or control panels become obsolete or unreliable, a full system replacement is not always required. We help organisations modernise automation systems safely, using a structured, phased approach that minimises disruption to production.

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Control System Modernisation Built Around Operational Reality

Many industrial sites operate with mechanically sound equipment controlled by ageing or unsupported automation systems. Unplanned failures, lack of spares, and limited system visibility increase operational risk and maintenance cost.

Stratos Control Systems specialises in targeted control system upgrades and refurbishments, allowing organisations to improve reliability and performance without unnecessary capital spend or extended downtime.

Our approach focuses on:

Risk reduction
Maintainability
Long-term system support
Clear documentation and handover

Common Control System Upgrade Challenges We Solve

We are frequently engaged to address issues such as:

Obsolete or unsupported PLC and SCADA systems
Control panels no longer meeting current standards
Increasing downtime and fault frequency
Limited documentation or system knowledge
High risk associated with full system replacement

By addressing these challenges methodically, we help organisations regain control of their automation systems.

Our Control System Upgrade & Refurbishment Services

Obsolete PLC & SCADA Replacement

We deliver planned PLC and SCADA replacement projects designed to reduce risk and minimise disruption.

Assessment of existing systems
Migration planning and strategy
Replacement using modern platforms
Parallel testing and phased changeover

Control Panel Refurbishment

Rather than replacing entire panels, we refurbish and modernise existing control panels where appropriate.

Panel rework and re-layout
Replacement of obsolete components
Improved labelling and safety
Upgrades to meet current standards

Automation System Modernisation

We modernise automation systems by upgrading key components while preserving existing machine functionality.

PLC and HMI upgrades
SCADA overlays for improved visibility
Integration with existing systems
Incremental system improvement

Phased Upgrade & Migration Strategies

For critical operations, upgrades must be carefully managed. We deliver phased and parallel upgrade strategies to maintain production continuity.

Step-by-step upgrade planning
Temporary parallel systems
Controlled change management
Reduced operational risk

Testing, Commissioning & Handover

Every upgrade or refurbishment project includes structured testing and clear handover.

Functional testing and verification
Site commissioning support
As-built documentation
Operator and maintenance guidance

Platforms & Systems We Upgrade

Platforms and systems we upgrade Allen Bradley.webp

Stratos Control Systems supports upgrades and refurbishments across a wide range of automation platforms, including:

Siemens
Allen Bradley
Mitsubishi

We also work extensively with legacy and specialist control systems, particularly as part of migration and modernisation projects.

Industries We Support

Our control system upgrade and refurbishment services support a wide range of industrial sectors, including:

Manufacturing
Food & Beverage
Pharmaceuticals
Packaging
Material Handling
Heavy Engineering

Each project is delivered with full consideration of industry-specific operational and regulatory requirements.

Why Choose Us for Upgrades & Refurbishment

Proven experience with legacy system upgrades
Structured, risk-managed approach
Strong focus on maintainability and documentation
Expertise across Siemens, Allen Bradley, and Mitsubishi platforms
Practical, site-focused engineering

We help organisations upgrade with confidence, not uncertainty.

The Result

Reduced risk. Improved reliability. Extended asset life.

Modern automation systems delivered without unnecessary disruption.

Control Panel Refurbishment Upgrade.webp

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Talk to Us About Control System Upgrades

Whether you are planning to replace obsolete PLCs, refurbish control panels, or modernise automation systems, Stratos Control Systems can help.

Plan a Control System Upgrade

Speak to engineers experienced in low-risk automation upgrades and refurbishments.