Legacy Control System Migration and PlantPAx Modernization

Legacy Control System Migration and PlantPAx Modernization

Industry: Feed/Grain/Oilseed
Project Type: Controls Modernization | Automation | Industrial Networking | Manufacturing Systems | Commissioning

Project Overview

A confidential feed, grain, and oilseed client needed to modernize legacy SY/MAX control systems supporting its Packing and Loading and Corn Mill operations. The project involved migrating the existing control systems to Allen-Bradley ControlLogix and upgrading legacy RSView32 and Citect applications to a modern PlantPAx HMI platform while maintaining production in a 24/7 operating facility.

Matrix Technologies developed a phased migration strategy that minimized downtime and adapted to limited outage windows and component availability challenges. The project also included network infrastructure upgrades, computing infrastructure modernization, distributed operator interfaces, historian implementation, and reporting enhancements to improve system reliability and operational visibility.

Scope of Work

Matrix Technologies provided engineering, procurement, construction management, controls integration, commissioning, and startup services for the complete controls modernization project.

The scope included migrating legacy SY/MAX PLCs to Allen-Bradley ControlLogix using custom termination PCB assemblies that allowed existing field wiring to be reused, significantly reducing installation time during planned outages. Matrix modernized the HMI platform by converting legacy RSView32 and Citect applications to PlantPAx and developed functional specifications to standardize PLC programming, HMI graphics, alarms, interlocks, and process controls.

Matrix also designed and implemented a new industrial Ethernet network serving the Packing and Loading, Corn Mill, Elevator, Blending, Packaging, and Steam areas of the facility. The project included new fiber and copper cabling, network panels, switches, physical servers, virtualization infrastructure, distributed operator workstations, FactoryTalk Historian, and Microsoft Power BI reporting.

To accommodate the facility's continuous operation, the original four-phase migration plan was revised to eight phased startups. Matrix coordinated engineering, construction, commissioning, and startup activities around scheduled outages to minimize production disruptions.

Project Results

The completed project replaced obsolete control systems with a standardized Allen-Bradley ControlLogix and PlantPAx architecture, improving system reliability, maintainability, and operational efficiency.

Through careful planning and phased execution, Matrix successfully completed the migration within the facility's limited downtime while minimizing disruption to production. The upgraded control system, industrial network, historian, and reporting tools provided plant operations, maintenance, and engineering teams with enhanced visibility into process performance and a scalable platform for future expansion.