{"id":1452,"date":"2026-06-10T09:05:03","date_gmt":"2026-06-10T07:05:03","guid":{"rendered":"https:\/\/www.tfsoleodinamica.it\/case-study\/plc-revamping-for-co-molding-press\/"},"modified":"2026-07-22T15:41:48","modified_gmt":"2026-07-22T13:41:48","slug":"plc-revamping-for-co-molding-press","status":"publish","type":"case-study","link":"https:\/\/www.tfsoleodinamica.it\/en\/case-study\/plc-revamping-for-co-molding-press\/","title":{"rendered":"PLC Upgrade on a Rubber Co-Molding Press \u2013 From Siemens S5 to S7-1200"},"content":{"rendered":"\n
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\u2699 Case Study \u00b7 Revamping & Industry 4.0<\/div>\n

PLC revamping on a rubber co-molding press
from Siemens S5 to S7-1200<\/span><\/h1>\n
\n Sector<\/strong> Presses \u00b7 rubber molding<\/span>\n Technologies<\/strong> Siemens S7-1200 \u00b7 PLC \u00b7 SCADA<\/span>\n TFS service<\/strong> Software development \u00b7 Overhaul<\/span>\n <\/div>\n <\/header>\n\n
\"TFS<\/figure>\n\n
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The technological shift of Industry 4.0<\/strong> 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.<\/p>\n\n

Revamping hydraulic presses: what it is and when it pays off<\/h2>\n

The revamping of a press<\/strong> is the modernisation of an existing machine \u2014 replacing obsolete PLC and SCADA systems<\/strong>, updating the control software and adding Industry 4.0<\/strong> integration \u2014 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<\/strong> at a fraction of the investment.<\/p>\n\n

The challenge<\/h2>\n

Many companies face a decision trade-off: allocating resources to purchase new equipment, or investing in revamping<\/strong> \u2014 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<\/strong> or carry a scarcity premium, and when downtime and discontinued software make the system increasingly difficult to manage.<\/p>\n\n

The TFS solution<\/h2>\n

TFS carried out a revamping project on a rubber co-molding press: the previous Siemens S5 PLC<\/strong> was replaced with a Siemens S7-1200<\/strong> controller, preserving the final intended use and the entire original physical structure of the machine. A targeted intervention that avoids replacing the equipment altogether.<\/p>\n

\"Siemens<\/figure>\n\n

The result<\/h2>\n

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.<\/p>\n\n

When revamping a press is worthwhile<\/h2>\n