Modernization of control systems

Industrial machines, machines, vision systems, sensor networks, controllers, robots, growing amount of data for processing, automated factories with complicated machine parks – it may be difficult to determine their life expectancy. Here we concentrate on decades of work guaranteeing the continuity of production. However, the modernization of the company’s equipment sooner or later will affect every company. Question – how much will an unexpected failure cost? Suddenly stopped production line, time needed for the supply new parts – can your company afford even a few hours of downtime meaning a real financial loss? In order to ensure reliable operation of the machine or production line, at least at the same level of performance and in compliance with the applicable standards, it is necessary to check and modernize the control systems in reasonable time. From an economic point of view, modernization itself will always be more profitable than purchasing new equipment.


  1. Ensuring the safety of machines and / or production lines in accordance with the latest legal requirements and technical solutions
  2. Increased production efficiency due to the use of modern solutions in control systems
  3. Ability to reduce costs and maintain traffic on the production line
  4. Improvement of financial results
  5. Guarantee of safety and reliability of production
  6. Elimination of potential threats resulting from currently used solutions


  1. When replacing / inserting additional safety components on the machine
  2. In the case of outdated control systems and the lack or difficult access to components due to the discontinuation of their production
  3. When changes were made to the machine during its operation, resulting from adapting to a changeable market, new types of orders or products without verification of these changes in terms of safety
  4. In the case of formal and legal requirements, eg. the machine does not meet the minimal requirements in accordance with the Machinery Directive and the relevant standards
  5. After the operators placed suggestions for improvements to the machine directly affecting ergonomics and work safety
  6. After identifying hazards caused by the currently used control system


  • 1. Modernization of machines in terms of safety:
    1. Modifying safety systems
    2. Modifying machine safety guards
    3. Adding light curtains
    4. The use of two-hand control panels
    5. Restrict access to machine zones
    6. Modification / application of permanent means of access to machines (stairs, access ladders, landings)
  • 2. Modernization of machines in functional terms:
    1. Modification and comprehensive replacement of machine control systems
    2. Extending the functionality of machines
    3. Expanding pneumatic systems
    4. Expanding hydraulic systems
    5. Replacement of drives with modern servo drives
    6. Addition of robotic stations
    7. Adding video control stations
    8. Renewing old machines
    9. Modification of product transport systems – chain, belt and roller conveyors
    10. Improvement of machine performance and quality


The process of modernizing control systems covers the scope from design to implementation, based on valid norms and directives and consists of several basic steps:

  1. Performing a safety audit to identify those on the machine.
  2. Presenting to the client proposals of solutions that are possible to use in a given situation.
  3. Implementation of the modernization project.
  4. Implementation of the proposed solutions.
  5. Starting the machine.
  6. Employee training related to newly introduced solutions.
  7. Consultations.

When choosing a modernization company, it is best to follow its many years of experience in this area, which guarantees you that the modernization works are at the highest level.