August 8, 2025

Overview
A large dairy products manufacturer faced critical operational risks at one of their facilities in the northeast United States due to aging control systems that had become increasingly unreliable and difficult to maintain. The facility’s cook room operations relied on legacy technologies from the 1980s and 1990s that had reached end-of-life status, creating significant vulnerabilities for continuous production. The plant operated with outdated RSView32 visualization software and obsolete Siemens TI PLC hardware that was no longer supported by the manufacturer. Years of undocumented modifications had created a complex web of systems controlled by oversized logic routines, making troubleshooting extremely challenging. With replacement parts becoming scarce and many critical components only available through unreliable secondary markets, the facility faced the constant threat of extended downtime that could severely impact production schedules and profitability.

Grantek, having established itself as the plant’s preferred control engineering partner through years of reliable support, was selected to lead a comprehensive modernization initiative that would transition the facility to current-generation automation technologies.

Challenges
The modernization project presented multiple complex technical hurdles that required careful planning and execution. The legacy infrastructure posed significant compatibility issues, with outdated communication protocols including coaxial, Peerlink, and RS232/422 serial connections that needed integration with modern systems.

Software Migration Complexities: The transition from TISoft and Siemens 505 Workshop programming environments to contemporary platforms required extensive code conversion and testing. Special function modules embedded within the legacy systems added additional layers of complexity to the migration process.
Electrical Infrastructure Issues: Decades of modifications had created a maze of undocumented wiring that needed to be traced, identified, and in many cases, completely replaced. Removing obsolete connections while maintaining operational continuity required meticulous planning and execution.
Process Documentation Gaps: Years of undocumented process changes meant that current operations differed significantly from original specifications. The absence of up-to-date P&ID drawings created additional risks during the transition, as plant personnel needed to rely on institutional knowledge rather than formal documentation.

Grantek evaluated multiple Rockwell Automation hardware solutions, including POINT I/O, FLEX I/O, ControlLogix I/O, and Compact 5000 I/O modules, ultimately recommending a ControlLogix PLC platform with Flex 5000 distributed remote I/O based on the client’s preference for Rockwell technologies and the solution’s scalability for future expansion.

Solutions
The implemented solution successfully addressed each critical pain point through a comprehensive technology upgrade that prioritized operational continuity and long-term maintainability.

Modern Software Platform Implementation: Grantek migrated the facility to FactoryTalk View SE network distributed SCADA, providing robust real-time monitoring and control capabilities across distributed systems. The new Studio 5000 integrated engineering environment streamlined programming workflows and offered advanced diagnostic capabilities that significantly reduced troubleshooting time.
Enhanced System Architecture: The ControlLogix PLC platform delivered modular flexibility and high-performance connectivity, operating reliably in extreme temperature ranges while supporting advanced diagnostic features. Real-time monitoring capabilities through Device Description files simplified maintenance procedures, while Removal and Insertion Under Power (RIUP) functionality minimized operational disruptions.
Comprehensive Documentation Update: All process and electrical drawings were updated to reflect current configurations, providing maintenance teams with accurate reference materials for future troubleshooting and system modifications.
Immediate Operational Benefits: Following the first phase completion, plant operations resumed seamlessly with personnel gaining complete system control. Maintenance routines and troubleshooting procedures became significantly more efficient due to updated documentation and improved diagnostic capabilities. The modernization project is ongoing, with the next phase scheduled for completion soon. This phased approach ensures minimal production disruption while systematically upgrading all legacy systems to current standards.
Future-Proofing Operations: The new platform provides enhanced security features including secure boot, user authentication, and role-based access control, protecting the facility’s intellectual property while preventing unauthorized system changes. The scalable architecture supports future engineering initiatives and expansion plans without the limitations imposed by legacy technologies.

This successful modernization demonstrates how strategic technology upgrades can transform operational reliability while positioning manufacturing facilities for continued growth and efficiency improvements. Grantek’s experience, and familiarity with the client helped deliver this solution that allows their facility to be more productive, while experiencing less downtime.