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How a Fertilizer Manufacturer Improved Reliability by Migrating from PLC-5/60 to ControlLogix

About the Client

The client is a long-established Indian company founded in 1967. With fourmanufacturing units, they are known for their research-driven work and have won national awards for technical innovation in dyestuffs, pesticides, veterinary drugs, andpolymers.

Requirements

The client wanted to upgrade their existing PLC-5/60 automation system to a modern ControlLogix setup. Their key objectives were:
• Evaluate the current PLC-5/60 system, including hardware, software, and overall functionality.
• Check which existing components could be reused and which needed replacement.
• Determine whether the existing I/O modules, communication modules, andother peripherals can be reused or if replacements are required.
• Plan and execute the installation of new hardware for their reaction automation system.
All of this needed to be done without interrupting the plant’s ongoing operations.

The Solution

MIPL completed the migration from PLC-5/60 to ControlLogix with a structured and reliable approach. The team delivered:
  • ControlLogix Redundancy: Upgraded the existing PLC-5/60 system to are dundant 1756-L7 controller
  • Modbus Communication: Installed two MicroLogix 1400 units for redundant Modbus communication with the DCS
  • Studio 5000 Migration: Transferred the previous PLC-5 program backup intoStudio 5000 for the new system
  • Comprehensive Evaluation:  Assessed the full hardware setup to determinereuse and ensure compatibility
This ensured a smooth transition to the new control system.

Key Outcomes

Improved Reliability
The upgraded control system operated more reliably and helped reduce unexpecteddowntime.
Better Scalability
The new platform made it easier for the client to expand or modify their automation system whenever needed.
Lower Maintenance Costs
Migration reduced maintenance expenses and the need for spare parts
Early Problem Detection
Real-time data collection and remote monitoring help catch issues before they become problems
Recognition & Trust
The project’s success earned MIPL a Service Appreciation Award and subsequentother orders for further upgrades.

Why the Client Chose MIPL

Proven Experience
Over 30 years of experience in automation and control systems with a strong trackrecord of successful projects.
Thorough Assessment
Comprehensive evaluation of existing hardware, software, and system compatibility ensures a tailored and cost-effective solution.