Automation retrofits modernize the controls on equipment that remains mechanically useful. TechControl evaluates the existing machine, documents the current behavior, and plans PLC, HMI, drive, I/O, panel, and network upgrades around a controlled production outage.
What an automation retrofit includes
- Obsolete PLC migration (PLC-5, SLC, MicroLogix) to CompactLogix
- HMI replacement and alarm rewrite
- VFD swap with cloned or improved parameter sets
- Panel rebuild where heat, spares, or code compliance is the issue
Common problems we solve
Retrofits address discontinued controllers, unavailable spares, unsupported software, failing HMIs, recurring drive faults, undocumented wiring, obsolete networks, weak diagnostics, and machines that cannot support new product, safety, or data requirements.
Our process
We begin with consultation, site assessment, backups, drawings, I/O mapping, and the existing sequence. The solution may include electrical design, panel drawings and fabrication, PLC/HMI development, factory testing, installation, commissioning, and final documentation. Timelines vary by hardware availability, machine complexity, shutdown window, and required production testing.
Technologies, industries, and service areas
Common retrofit work includes Allen-Bradley PLC-5, SLC, MicroLogix, CompactLogix, ControlLogix, Studio 5000, FactoryTalk View, PanelView, PowerFlex, EtherNet/IP, Siemens, and Omron systems. We support manufacturing, automotive, food and beverage, packaging, pharmaceutical, material handling, plastics, warehousing, and industrial processing throughout the GTA, Canada, and Europe-based projects.
Frequently asked questions
Can an existing machine be upgraded instead of replaced?
Often, yes. The decision depends on mechanical condition, safeguarding, throughput, product requirements, and the current controls risk.
Do you preserve the existing sequence?
We document and validate the current machine behavior before conversion, then test the replacement system against normal and fault conditions.
Can retrofits be staged?
Yes. Some projects phase controller, HMI, drive, or panel work around planned outages.
Do you provide startup support?
Yes. Retrofits can include machine commissioning and production handoff.
Read PLC modernization versus machine replacement and when to upgrade an old PLC.