# PLC and safety migration for a bottling line

> Controls and safety migration of a running bottling line for a regional beverage producer, executed inside planned shutdown windows.

Page: https://ganiindustrial.com/cases/bottling-line-controls-migration · Language: en

A bottling line that has run for fifteen years usually still works. What has stopped working is the supply chain behind its controls: the PLC generation is out of production, the safety concept predates the current standards, and a single failed module can idle the line for a week while a used part is found.

This programme replaced the controls and the safety system on a running line. The machines, the conveyors and the process stayed; the PLC, the safety architecture and the operator interface were renewed, and the line came back producing the same product to the same recipe.

It was done inside planned shutdown windows, in sections, with a defined way back at each step. That is the whole point of the job: a beverage producer cannot stop selling while its line is modernised, so the migration has to fit into the weekends the plant already schedules.

## Starting point

The line ran on a discontinued PLC family with no spares path and an outdated safety concept. The producer could not accept extended downtime: filling continued in season, so every step had to fit weekend shutdowns with a guaranteed way back.

A twenty-year-old line with fragmented documentation, a mix of hardwired safety and legacy controls, and no current electrical drawings.

## What we need from you

- Access to the line for survey during planned stops
- Remaining original documentation and modification history
- Production calendar with agreed shutdown windows
- List of known faults and operator workarounds

## Our scope

- On-site survey and re-documentation of the existing installation in EPLAN
- Migration concept split into reversible weekend packages
- New PLC and safety architecture with pre-built and pre-tested panels
- Stepwise changeover with rollback plan per window
- Commissioning, operator briefing and updated documentation

## Outcome

- Migration completed inside the planned shutdown windows
- Line handed back to production after each window without carry-over work
- Current EPLAN documentation established as the new baseline
- Follow-on support agreement for the migrated installation


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