CASE STUDY
Legacy PLC5 to ControlLogix Migration for High-Volume Beverage Line
Global beverage manufacturing facility (Fortune 500 Consumer Packaged Goods company)
Beverage – Alcoholic Beverages
Electrical Design & Drafting; PLC Programming & Modernization; HMI Development; Field Startup & Commissioning Support
Overview
TM Process & Controls, Inc. (TMPC) was engaged to modernize a legacy control system supporting the production of a well-known vodka brand. The effort included the conversion of both main and remote 1771 chassis from PLC5 to ControlLogix PAC architecture, with upgraded communications across DeviceNet, ControlNet, Modbus, and Remote I/O protocols. Engineering deliverables included detailed electrical schematics, control logic, network diagrams, and HMI updates to align with facility-wide standards.
Problem
A critical beverage production line was operating on obsolete PLC5 hardware, posing risks to reliability, maintainability, and future integration with batch control systems.
Solution
TMPC designed and implemented a complete PAC migration using ControlLogix, leveraging produce/consume messaging where possible. All devices across multiple protocols were mapped to new hardware modules. Updated HMIs and coordinated field startup ensured a seamless transition with minimal production downtime.
Results
- Modern, supportable control system platform (ControlLogix)
- Standardized HMI aligned with other production areas
- Future-ready architecture with integrated flow meter and batching capabilities
- Improved diagnostics and maintainability
- Successful cutover with support through water and small batch production testing
