Weetabix PLC & HMI Upgrade
​PLC, Safety System and SCADA Upgrade for Cooker Control Systems
Stratos Control Systems delivered a PLC and HMI upgrade for the Weetabix Corby Cooker line to eliminate control system obsolescence and ensure long-term operational reliability. The project involved safely installing modern hardware, improving spare parts availability, and supporting a structured migration away from legacy PLC platforms. This upgrade reduced operational risk, improved maintainability, and enabled Weetabix to future-proof critical production assets.
01
The Problem
Weetabix’s cooker control systems relied on obsolete PLC and HMI hardware, creating reliability and support risks due to limited spare part availability. The safety system did not meet current standards and lacked proper integration, with emergency stops unable to fully isolate equipment.
Control panels were rusting, shared isolators, and were not designed for modern hygienic environments. The system provided minimal visibility, with limited HMI information, no structured alarms, no data capture, and heavy reliance on manual operation.
As a result, operators were required to remain close to equipment throughout production, increasing reliance on manual supervision and operational risk.
02
Scope of Work
Phase 1 – Audit & Risk Review
Stratos Control Systems conducted a full assessment of the existing cooker control systems to identify risks, limitations, and upgrade requirements.
​
This included:
-
Review of existing PLC and HMI hardware
-
Identification of obsolete components
-
Assessment of existing safety system design
-
Review of control panel construction and suitability
-
Evaluation of existing control functionality and process visibility
​
This phase established the technical requirements and upgrade strategy for the system modernisation.
Phase 2 – Upgrade Strategy
Based on the audit findings, Stratos developed a structured upgrade strategy to modernise the control and safety systems while improving automation capability and maintainability.
​
The upgrade strategy included:
-
Replacement of obsolete PLC and HMI hardware
-
Design and implementation of a new safety system
-
Redesign of control panels using stainless steel construction
-
Introduction of SCADA-based monitoring and control
-
Implementation of structured alarms and notifications
-
Development of automated process control
-
Introduction of recipe-based production management
-
Integration of improved system interlocking and control logic
​
This provided a modern, structured automation platform aligned with current operational and safety requirements.
Phase 3 – Implementation
Stratos implemented the new automation and control system, replacing obsolete infrastructure and introducing modern monitoring and automation capability.
​
Implementation included:
-
Installation of new PLC and HMI hardware
-
Implementation of redesigned safety system
-
Installation of new stainless-steel control panels
-
Deployment of SCADA monitoring and control system
-
Implementation of alarm monitoring and notification functionality
-
Introduction of automated process control and recipe management
-
System commissioning and operational integration
​
The upgraded system improved operational visibility, safety compliance, and engineering maintainability.
03
Platforms Used
The project utilised modern automation and control system technologies, including:
​
-
HMI operator interface systems
-
SCADA monitoring and control system
-
Stainless steel hygienic control panels
-
Structured control system architecture
-
Integrated alarm and monitoring functionality
​
These technologies provided improved system reliability, visibility, and maintainability.
04
Outcomes & Metrics
The upgrade delivered significant operational and engineering improvements for the cooker control systems at Weetabix.
​
Key outcomes included:
-
Removal of obsolete PLC and HMI hardware risks
-
Improved safety system compliance and integration
-
Improved system visibility and operational monitoring
-
Introduction of structured alarms and notifications
-
Improved automation and reduction in manual processes
-
Improved engineering diagnostics and system access
-
Improved maintainability and long-term support capability
​
The new system provides a modern automation platform to support ongoing production and maintenance operations.
Testimonial
“The upgrade significantly improved our control capability and provided improved visibility and operational control. The new system has improved safety, monitoring, and maintainability of the cooker control systems.”
​
Site Engineering Team
Weetabix
