Industrial Automation Modernisation
- Mar 9
- 3 min read
Updated: Mar 25
The Shift Towards Modern Industrial Automation Systems
Across manufacturing and industrial sectors, more facilities are investing in industrial automation modernisation to improve performance, reduce downtime, and future-proof their operations.
Legacy automation systems may still function, but they often introduce hidden risks, inefficiencies, and long-term costs.
Understanding why facilities are modernising their automation systems, and how to approach it — is key to maintaining reliable and scalable operations.
What Is Industrial Automation Modernisation?
Industrial automation modernisation involves upgrading or improving existing control systems, including:
Industrial communication networks
Rather than full system replacement, modernisation focuses on targeted upgrades that improve performance while minimising disruption.
Why Facilities Are Modernising Their Automation Systems
Obsolete Hardware & Unsupported Systems
Many facilities rely on legacy PLCs and control systems that are no longer supported.
Issues:
Limited availability of spare parts
Manufacturer support discontinued
Increased risk of system failure
Impact:
Unexpected failures can lead to extended downtime and costly repairs.
Increased Downtime & Reliability Issues
As systems age, failure rates increase.
Common problems:
Frequent breakdowns
Intermittent faults
Unreliable system performance
Impact:
Production interruptions, lost output, and increased maintenance costs.
Lack of System Visibility
Older systems often lack real-time monitoring capabilities.
Issues:
Limited or no SCADA integration
Poor alarm management
No performance data tracking
Impact:
Problems go undetected until they cause downtime.
Poor Integration with Modern Systems
Legacy systems struggle to integrate with:
New machinery
Modern PLC platforms
SCADA and data systems
Impact:
Disconnected systems and inefficient operations.
Difficult Maintenance & Fault Finding
Outdated systems are often:
Poorly documented
Structurally unclear
Hard to troubleshoot
Impact:
Longer downtime during faults and increased reliance on specialist knowledge.
Increased Operational Costs
Maintaining legacy systems becomes more expensive over time:
Cost of specialist repairs
Increased downtime
Inefficient processes
Impact:
Higher long-term operating costs compared to modern systems.
Benefits of Modernising Industrial Automation Systems
Modernisation delivers significant improvements:
Reduced downtime and improved reliability
Better system visibility and monitoring
Easier maintenance and fault finding
Improved system performance and efficiency
Scalability for future expansion
How to Modernise Industrial Automation Systems
A structured approach ensures successful modernisation with minimal disruption.
PLC Upgrades & Migration
Replace obsolete PLC hardware
Upgrade to modern, supported platforms
Improve control logic and performance
Learn more about PLC upgrades and migration
Control System Upgrades
Upgrade control panels and electrical systems
Improve layout, wiring, and documentation
Ensure compliance with current standards
SCADA & Monitoring Implementation
Introduce real-time monitoring and control
Improve visibility across systems
Enhance alarm management and diagnostics
Discover SCADA and HMI systems
Phased Modernisation Strategy
Upgrade systems gradually
Reduce operational risk
Minimise downtime during implementation
Real-World Example
Before Modernisation:
Legacy PLC system
Limited monitoring
Frequent faults and downtime
After Modernisation:
Upgraded PLC platform
Integrated SCADA system
Improved system reliability and visibility
Result: reduced downtime and improved operational efficiency
Common Mistakes When Modernising Automation Systems
Delaying upgrades until failure occurs
Replacing systems without a clear strategy
Ignoring integration requirements
Choosing short-term fixes instead of long-term solutions
Key Reasons Facilities Are Modernising
Obsolete and unsupported hardware
Increasing downtime and reliability issues
Lack of system visibility
Integration limitations
Difficult maintenance and fault finding
Rising operational costs
Frequently Asked Questions
What is industrial automation modernisation?
It involves upgrading existing control systems to improve performance, reliability, and integration with modern technologies.
When should automation systems be upgraded?
Systems should be upgraded when they become unreliable, unsupported, or difficult to maintain.
What are the benefits of modernising control systems?
Improved reliability, reduced downtime, better visibility, and lower long-term costs.
Can automation systems be upgraded without full replacement?
Yes, many systems can be modernised in stages to minimise cost and disruption.
How long does automation modernisation take?
Timelines vary depending on system complexity, but projects are designed to minimise downtime.
Modernise Your Automation System
If your automation system is outdated or causing operational issues, we can help you modernise it with minimal disruption.
