Control System Upgrades

Over the years, LTS has successfully completed numerous industrial control system upgrades, replacing outdated, obsolete, or unsafe control systems with modern, reliable automation solutions. Many industrial facilities continue to rely on machinery and processes that remain mechanically sound but are limited by aged control systems, obsolete PLC hardware, or unsupported software.

One of the most common challenges with older systems is the lack of documentation, including missing electrical drawings, unavailable PLC and HMI program backups, and limited understanding of how the original system was designed. These issues can make maintenance, fault finding, and upgrades difficult for plant operators and engineers.

At LTS, we specialise in resolving these challenges. Even when no drawings, schematics, or PLC backups are available, our experienced engineers can analyse the existing system, reverse engineer the control logic, and develop new electrical designs and PLC software to fully modernise the control system.

Our control system upgrade services allow businesses to extend the life of their equipment while significantly improving performance, safety, and reliability. During an upgrade project we can:

• Replace obsolete PLC and HMI systems
   
• Create new electrical schematics and documentation
   
• Develop new PLC and HMI software
   
• Improve machine safety systems and compliance
   
• Add new functionality, automation features, or process monitoring
   
• Improve system reliability and maintainability
   

By upgrading the control system rather than replacing the entire machine, companies can often achieve significant cost savings while benefiting from modern automation technology.

If your equipment or process remains mechanically sound but is limited by an outdated control system, a modernisation project can provide excellent value for money while improving safety, efficiency, and long-term maintainability.