Legacy Control System Migration and PlantPAx Modernization

Legacy Control System Migration and PlantPAx Modernization

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

Project Overview

A confidential feed, grain, and oilseed client needed to modernize the legacy SY/MAX control systems running its Packing and Loading and Corn Mill operations. The facility operates 24/7, so the migration had to happen without interrupting production.

Scope of Work

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

• PLC migration: Replaced legacy SY/MAX PLCs with Allen-Bradley ControlLogix. Custom termination PCB assemblies let the existing field wiring be reused, which cut installation time during outages.
• HMI modernization: Converted the legacy RSView32 and Citect applications to PlantPAx. Functional specifications standardized PLC programming, HMI graphics, alarms, interlocks, and process controls.
• Network and infrastructure: Built a new industrial Ethernet network serving the Packing and Loading, Corn Mill, Elevator, Blending, Packaging, and Steam areas. This included fiber and copper cabling, network panels, switches, physical servers, virtualization, and distributed operator workstations.
• Data and reporting: Implemented FactoryTalk Historian and Microsoft Power BI reporting.

Limited outage windows and component availability issues led to revising the original four-phase plan into eight phased startups, each scheduled around planned outages.

Project Results

The client now runs on a standardized ControlLogix and PlantPAx architecture that is more reliable and easier to maintain. The migration finished within the facility's limited downtime with minimal disruption to production. The new network, historian, and reporting tools give operations, maintenance, and engineering better visibility into process performance and a platform that can grow with the plant.