Industrial
Controls Retrofit That Revived an Aging Production Line
A controls modernization that restored uptime and added diagnostics to a mechanically sound but obsolete line.
The problem
A manufacturer relied on a production line whose mechanics were still sound but whose controls were obsolete. Spare parts were hard to source, unplanned downtime was rising, and the aging system offered no diagnostics to speed troubleshooting.
A full replacement would have been expensive and disruptive, taking a working line out of production for an extended period.
Our approach
Cerebrus retrofitted the line with a modern control platform — current PLCs, drives, and sensing — and designed and built new UL 508A listed control panels to replace the outdated electrical system.
We added a new operator interface with clear status, alarms, and diagnostics, and programmed the sequencing and safety to current expectations, all while preserving the mechanically sound machinery already in place.
The result
The line returned to reliable operation on well-supported, sourceable components, and unplanned downtime dropped as the new diagnostics let staff pinpoint issues quickly.
The manufacturer extended the useful life of the equipment at a fraction of replacement cost, and gained the data and safety improvements of a modern control system.
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