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Packaging line panel and PLC upgrade
Regional food manufacturer · Food & beverage · 1 min read · March 20, 2026
Replaced aging relays and a undocumented PLC with a documented panel, HMI and spare strategy.
- ▸Unplanned stops on the cell dropped after the first month
- ▸Operators gained a clear alarm list instead of a tower light
- ▸Engineering now has comments, backups and spare I/O
The line stopped on undocumented interlocks and a CPU with no backups. We surveyed I/O, rebuilt the control panel, migrated logic and trained operators on a new HMI.
Cutover happened during a planned sanitation window. The old CPU remained as a rollback for 72 hours.
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