Conveyor system modernisation
About the project
Modernisation of 120 metres of conveyor route in running production — work took place during planned shutdowns so production never stopped.
We replaced the frequency inverters, deployed a new PLC and created a control-room visualisation with fault diagnostics per section.
This also included updating as-built documentation and training the maintenance team.
Brief and challenge
Obsolete control technology caused unplanned downtime, but production could not be stopped for longer than a weekend window.
Our solution
- Analysis of the existing state and splitting the retrofit into weekend shutdowns.
- Replacement of frequency inverters and migration to a Siemens S7-1200 PLC.
- New SCADA visualisation for the control room with per-section fault diagnostics.
- Updating as-built documentation and training maintenance staff.
Project course
- 01
Analysis
Mapping existing cabling, drives and control logic, shutdown planning.
- 02
Retrofit
Phased replacement of inverters and cabinets, section-by-section PLC rollout.
- 03
Visualisation and service
SCADA for the control room, maintenance training, subsequent service supervision.
Result
- The modernisation was completed without any loss of production time.
- Maintenance can locate a fault to a specific section within seconds.
- Reduced unplanned downtime of the conveyor route.
We share detailed project parameters on request, to the extent permitted by our contractual arrangements with the customer.