Automation Applications

Automation PLC Upgrades | PLC5 to ControlLogix IO Conversion for Consumer Goods

Production down time was not an option for our client. EPIC’s automation and controls team worked around the clock for seven consecutive weekends, to not interrupt the clients weekly production schedule. EPIC’s team preformed automation PLC upgrades by converting outdated PLC5 chassis and associated I/O to the new ControlLogix platform without impacting scheduled production.

CLIENT: Fortune 500 Consumer Products Company

INDUSTRY: Chemical/Manufacturingautomation plc plant worker



  • Electrical schematics were incomplete or did not exist
  • Multiple power sources that where fed from un marked sources
  • Some I/O didn’t function before the migration, therefore additional diagnostics where needed
  • Hundreds of I/O points rewired in phases

A saying often used in manufacturing circles is “Production is King”. Unplanned stoppages in production are costly and create scheduling issues for subsequent production runs. Because our clients product was needed to fill the shelves of major general merchandises stores, production could not be interrupted.

EPIC successfully upgraded the customers control system without impacting scheduled production. Similar to a NASCAR pit crew, EPIC’s team was “all hands on deck” for short stints on the weekends – executing one complete conversion per weekend – for seven consecutive weekends. EPIC also uncovered and corrected existing programming issues that left the customer with a more reliable solution, eliminating unnecessary legacy code.


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EPIC Industrial Automation
4134 Meramec Bottom Rd
St. Louis, MO 63129, US
(314) 845-0077