Sack Plant Automation System
PLC Retrofitting & Control Panel Modernization
This project involves the retrofitting and modernization of the Sack Plant Automation System
to upgrade legacy control infrastructure and improve overall plant reliability.
The scope included migration from an existing Siemens S5 PLC platform
to a modern Siemens S7-based automation system, ensuring long-term
supportability and enhanced performance.
The retrofit solution was carefully engineered to minimize production downtime
while preserving existing field wiring and plant logic wherever feasible.
Advanced control features, improved diagnostics, and operator-friendly interfaces
were introduced to enhance operational efficiency in the sack manufacturing process.
The upgraded system is built using Siemens PLC S7-300 with a
modern HMI interface and a newly designed PLC control panel.
This architecture provides improved visibility, easier maintenance,
and seamless integration with existing plant equipment.
Execution Scope
- Retrofitting of existing sack plant automation system
- Migration from Siemens S5 PLC to Siemens S7-300 PLC
- Development and testing of upgraded PLC application software
- HMI design for operator monitoring and control
- Design, manufacturing, and commissioning of new PLC control panel
Technology Used
Legacy PLC: Siemens S5 (Retrofitted)
Upgraded PLC: Siemens PLC S7-300
Operator Interface: HMI-based monitoring and control
Control Hardware: New PLC control panel
Key Benefits
- Extended life of sack plant through PLC modernization
- Improved system reliability and ease of maintenance
- Enhanced operator visibility via modern HMI interface
- Reduced downtime with structured diagnostics and alarms
- Future-ready automation platform for further expansion
Our Happy Customer
BILT Graphic Paper Products Ltd. (BGPPL)
Ashti Unit, Maharashtra
