PLC revamping on a rubber co-molding press
from Siemens S5 to S7-1200
The technological shift of Industry 4.0 has pushed many companies to rethink their production processes. For hydraulic systems, the need is for solutions that combine tailor-made flexibility, efficiency without the risk of obsolescence, and a sustainable return on investment with increasingly short payback periods.
Revamping hydraulic presses: what it is and when it pays off
The revamping of a press is the modernisation of an existing machine — replacing obsolete PLC and SCADA systems, updating the control software and adding Industry 4.0 integration — while keeping the original mechanical structure and hydraulic system. It pays off when spare parts for the installed control system are unobtainable, when downtime and out-of-production software make the machine unmanageable, or when the press needs to be connected without bearing the cost of a new machine. The result is a connected, maintainable press, ready for Industry 4.0 at a fraction of the investment.
The challenge
Many companies face a decision trade-off: allocating resources to purchase new equipment, or investing in revamping — upgrading existing machines and systems that still have adequate residual service life. Revamping becomes the optimal choice when spare parts for the installed PLC and SCADA systems are unobtainable or carry a scarcity premium, and when downtime and discontinued software make the system increasingly difficult to manage.
The TFS solution
TFS carried out a revamping project on a rubber co-molding press: the previous Siemens S5 PLC was replaced with a Siemens S7-1200 controller, preserving the final intended use and the entire original physical structure of the machine. A targeted intervention that avoids replacing the equipment altogether.
The result
The system is fully connected again and ready for Industry 4.0: real-time data and aggregations from the machines, optimised planned maintenance, and a sharp reduction in breakdowns and downtime. All of this with a contained investment compared with purchasing a new machine, and a rapid payback.
When revamping a press is worthwhile
- Production control requires real-time data and aggregations from the machines
- The time spent on planned maintenance is growing exponentially
- Frequent breakdowns and downtime can no longer be handled by in-house maintenance
- The PLC/SCADA software is out of production and no longer supported
- Production and set-up times no longer allow adequate output
TFS technologies and services involved
Do you have a system to modernise?
Let’s assess together whether revamping is the right solution for your production.
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