Roto-Moulding Machine Control System Upgrade

A complete controls overhaul delivered within a tight timeframe - modernising an ageing system with smart diagnostics, wireless comms, and a future-ready architecture.

The challenge

An ageing PLC and legacy computer system had reached the end of its useful life. With no recipe management, limited diagnostics and poor fault visibility, the machine was becoming a bottleneck for production. The client needed a full overhaul — delivered without disrupting an already tight production schedule.

What we delivered

Siemens PLC & HMI

New custom program built for current needs with headroom for future expansion

New control panels

Designed and installed throughout the machine for clean, reliable operation

Wireless comms

Point-to-point wireless between remote sections — less cabling, more flexibility

Recipe management

Integrated system for fast, accurate product changeovers with minimal operator input

Smart documentation — a first for this project type

QR-coded barcodes inside each control panel door give maintenance and engineering teams instant mobile access to panel drawings, VSD parameters and live documentation — right at the point of use. No more hunting for outdated paperwork. Faster troubleshooting, fewer errors, and the latest information always available on site.

Outcomes

↓ Downtime

Faster faults, smarter diagnostics, instant doc access

↑ Throughput

Recipe management speeds up changeovers significantly

On time

Full delivery within a tight production schedule

Despite a short turnaround, the team delivered a modern, reliable system that improves efficiency, safety and maintainability — with innovations that set the standard for future projects.

Project delivery team