⚙ Case Study · Revamping & Industry 4.0

PLC Revamping on a Rubber
Co-Molding Press from Siemens S5 to S7-1200

Presses & Rubber Molding Sector · Siemens S7-1200 Technologies · PLC · SCADA TFS Service Software Development · Revamping
Revamping PLC TFS su pressa di co-stampaggio gomma

The technological revolution of Industry 4.0 has prompted many companies to rethink their production processes. For hydraulic systems, there is a growing need for solutions that combine customized flexibility, efficiency without the risk of obsolescence, and a sustainable return on investment with increasingly shorter payback periods.

The Challenge

Many companies face a decision-making trade-off: allocate resources to purchase new equipment or focus on revamping—upgrading existing machines and systems with adequate remaining useful life. Revamping becomes the optimal choice when spare parts for installed PLCs and SCADA systems are unavailable or subject to a premium price due to scarcity, and when machine downtime and end-of-life software make the system increasingly difficult to manage.

The TFS Solution

TFS implemented a revamping project on a rubber co-molding press: the previous Siemens S5 PLC was replaced with a Siemens S7 Model 1200 microprocessor, preserving the system’s intended end use and its entire original physical structure. A targeted intervention that avoids the complete replacement of the machinery.

Quadro di controllo PLC Siemens S7-1200 dopo il revamping TFS

The Result

The system is now fully interconnected and ready for Industry 4.0: real-time data and analytics from the machines, optimized planned maintenance, and a drastic reduction in breakdowns and downtime. All this with a modest investment compared to purchasing a new system and a rapid payback.

When Revamping Makes Sense

  • Production control requires real-time data and aggregates from the machines
  • The time spent on planned maintenance is growing exponentially
  • Frequent breakdowns and machine downtime, no longer manageable by in-house maintenance
  • PLC/SCADA software is end-of-life and no longer supported
  • Production and setup times do not allow for adequate production

TFS technologies and services involved

Do you have a system that needs modernizing?

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