Facts & Hacks Vol. 2
Industrial operations today depend heavily on automation and control systems. Yet, many facilities continue to operate with outdated control panels that pose serious risks to uptime, cost efficiency, and long-term growth. In fact, over 50% of industrial control systems globally are over 10 years old, and more than 40% of SME (Small-Medium sized Enterprise) manufacturing equipment is over 15 years old, often relying on legacy PLCs that lack compatibility with modern protocols. Some estimates place the value of still-operating legacy systems in the $16–18 billion range, with products like Honeywell’s TDC3000 still in use from the 1980s and ‘90s. These aging systems represent tens of thousands of plants and potentially hundreds of thousands of outdated PLCs still in operation. Given that many of these systems were rated with a 10-year MTBF (Mean Time Between Failure), much of this infrastructure may now be operating on borrowed time. This white paper outlines the consequences of failing to upgrade aging control systems and the transformative benefits of modernization. With careful planning and the right partner, upgrading your control panels is not just an improvement — it’s a strategic move for future success.
The Risks of Not Upgrading Control Panels
Failing to upgrade legacy control panels can lead to significant operational and financial challenges. These risks include:
1. Unplanned Downtime
Old components are more prone to failure. When a system goes down unexpectedly, production halts — often for hours or even days — leading to missed deadlines and lost revenue.
2. Component Availability
As manufacturers phase out older technologies, replacement parts become harder to find or are discontinued entirely. This increases lead times and inflates costs.
3. Expedited Service Costs
In urgent breakdown scenarios, rushed service calls, overnight shipping, and emergency labor quickly multiply costs — all preventable with proactive upgrades.
4. Incomplete or Outdated Documentation
Older systems often lack updated wiring diagrams, schematics, and program backups. This makes troubleshooting slow and costly, especially if original designers are no longer available.
Why Upgrading Makes Sense Now
Modernizing your control panels is more than a maintenance move — it’s a strategic investment in your facility’s future. Key benefits include:
1. Minimized and Planned Downtime
With a structured upgrade schedule, downtime is predictable and planned during non-critical windows — avoiding costly surprises.
2. Readily Available Components
Modern panels use standardized, widely available parts that reduce lead time and simplify maintenance.
3. Improved Energy Efficiency
Newer control technologies consume less energy, helping reduce utility bills and support sustainability goals.
4. Modern Documentation and Code
Upgrades provide an opportunity to document every aspect of the system — drawings, wiring diagrams, control logic — creating a clear roadmap for future service and expansion.
5. Expansion and Optimization
New systems offer greater flexibility and scalability, allowing you to improve processes and add functionality.
6. Lower Maintenance Costs
Modern components are built for longevity, with self-diagnostics and fewer failures, reducing the need for reactive maintenance.
“Plan for the future, build for the now.”
Conclusion & Call to Action
Continuing to operate with outdated control panels is a silent drain on productivity and profits. Each unexpected failure or service delay chips away at your bottom line. Worse, without predictability, you lose the ability to plan effectively — risking not just equipment, but your business reputation.
Trola specializes in designing modern control solutions that help manufacturers transition into the next generation of production. Our team will assess your current systems, identify vulnerabilities, and craft a tailored upgrade plan to align with your goals.
Here’s what you can do about it — starting now:
- Get the Facts on Paper: Trola can reverse-engineer your system to create as-built wiring drawings and bills of materials — giving you clarity, accuracy, and compliance.
- Download and Modernize Your PLC Programs: We extract your existing PLC code and convert it to modern, fully supported platforms that are scalable, efficient, and cyber secure.
- Upgrade to Meet the Code: Every upgrade is engineered to meet current UL and NFPA standards, protecting your facility from costly code violations or safety infractions.
- Avoid Emergency Costs with Planned Work: A proactive upgrade plan means no surprises, no overnight freight, and no lost weekends for your maintenance crew.
- Get Back to Growing, Not Repairing: New control systems are easier to maintain, consume less energy, and are designed to support future expansion.
Don’t wait for the next failure to make a change.
Contact Trola today for a private consultation and discover how we can help you plan for the future while building for the now.