Modernizing Critical Production Lines Before Obsolete Controls Become a Costly Failure

When a Long-Planned Modernization Can’t Wait Much Longer

For many manufacturers, controls modernization has been on the list for years. Aging equipment continues to run, maintenance teams find ways to support it, and other priorities make it easy to push an upgrade into another budget cycle.

Eventually, the risks begin to add up as replacement parts become harder to source, vendor support declines, and a single component failure has the potential to cause significant downtime.

A major pet food manufacturer had reached that point with two critical production lines still relying on DeviceNet communications and aging motor control hardware. Rather than waiting for a failure to dictate the timeline, the manufacturer planned and budgeted for the modernization in advance.

Actemium Avanceon helped replace the obsolete controls, migrate the lines to a modern Ethernet/IP architecture, and improve long-term reliability through a phased implementation designed to minimize production downtime.

The Challenge

Two of the manufacturer’s critical production lines relied on a DeviceNet control architecture that had become increasingly difficult to support as the technology reached the end of its lifecycle.

Although the lines remained operational, the facility faced:

• Obsolete DeviceNet communications with limited vendor support
• Aging VFDs and motor control hardware nearing end of life
• Increasing difficulty sourcing replacement parts
• Lengthy and complex troubleshooting
• Greater risk of prolonged downtime if a critical component failed

Because the manufacturer acted before a major failure occurred, the team could approach the modernization strategically rather than reactively, planning the investment and coordinating the work around scheduled production outages.

The Solution

Actemium Avanceon developed a controls modernization strategy that replaced obsolete technology while accounting for the realities of upgrading two active production lines.

The project included:

• Electrical design, including layouts, schematics, network architecture, and bills of material
• Hardware procurement for new VFDs, motor starters, overload relays, and associated components
• PLC programming and HMI development
• Migration from DeviceNet to Ethernet/IP
• Installation coordination and field verification
• Commissioning, startup, and on-site production support

To minimize production impact, the modernization was completed in two planned phases, allowing each line to be upgraded during shorter scheduled outages.

Modernizing Without Replacing What Still Works

The new controls also needed to integrate with an existing safety system built around older hardware and wiring. This required careful engineering to preserve the necessary safety functionality while avoiding unnecessary replacement of equipment that continued to perform reliably.

The upgraded system incorporated Ethernet/IP communications, Rockwell PowerFlex 525 and 753 variable frequency drives, Rockwell E300 electronic overload relays, managed Stratix 5200 industrial network switches, Rockwell POINT Safety I/O, and updated PLC programming and HMI applications.

The result was a modern, maintainable controls platform that addressed the greatest areas of risk without replacing equipment that still had value.

The Results

The modernization eliminated the remaining obsolete controls from both production lines and reduced the long-term operational risk associated with aging technology.

The project:

• Eliminated unsupported DeviceNet communications, reducing reliance on obsolete technology
• Reduced risk associated with obsolete controls and aging hardware
• Improved troubleshooting and long-term maintainability
• Increased availability of replacement components
• Improved reliability for two critical production lines
• Minimized production disruption through planned, phased outages

Most importantly, the manufacturer was able to complete the modernization on its own timeline, coordinating the investment and outages around production needs rather than being forced to react to an unexpected failure.

Why This Matters

Controls modernization is easy to postpone when the existing system is still running, but “still running” does not always mean “still supportable.” As technology ages, spare parts become harder to find, support declines, and the options available after a failure become increasingly limited.

Addressing those risks before an outage gives manufacturers more control over what gets replaced, when the work happens, and how the investment is phased. For this manufacturer, that meant turning a long-recognized need into a planned modernization that improved reliability without unnecessary production disruption.

Move Modernization from the List to the Plan

If aging controls, unsupported hardware, or legacy communication networks have been on your facility’s list for years, now may be the time to understand where the greatest risks are and what should be addressed first.

Actemium Avanceon helps manufacturers develop practical modernization strategies around existing equipment, production schedules, and long-term supportability.

Ready to take a closer look at your modernization priorities? Contact our team to start the conversation.