Modernizing a Multi-Level Industrial Mixing Line
The Challenge
A leading rubber compounding facility was operating a critical mixing operation using a legacy Allen-Bradley PLC-5 architecture. The system’s intelligence was fragmented across three different elevations—the ground floor drive room, a mezzanine seal oil system, and a second-story mixer cab and scale control panel.
Intra-system communication relied on aging Universal Remote I/O (RIO) and this included multiple racks of 1771-series I/O as well as aging Mettler Toledo Jaguar scale controllers. Further communication came from the PLC-5 racks to equipment like variable frequency drives (VFDs) over other legacy protocols and interface cards. Two separate smaller controllers, a CompactLogix and an older ControlLogix connected to the PLC-5/40 and enabled ethernet connectivity to valve systems, the mixer drives, and on to the site’s Manufacturing Execution System (MES). This decentralization created significant hurdles for troubleshooting, data visibility, and long-term maintenance.
The Solution: A Turnkey Modernization
Imperium Technology Solutions was tapped to lead a complete turnkey controls upgrade. The goal was to collapse three independent control systems into one unified, high-performance platform while migrating all field communications to Ethernet/IP.
Engineering & Integration:
Imperium’s engineering team consolidated the logic from three legacy controllers into a single Allen-Bradley ControlLogix 5580 (L83E). This powerful, centralized controller would be located safely in the first-floor drive room and connect to the remote mezzanine and second floor I/O and other devices via high speed Ethernet communications.
The hardware overhaul included:
1st Floor: Design, fabrication, and installation of a new control panel with 17-slot ControlLogix chassis, high-speed Ethernet bridge, and drive interface modules.
Mezzanine: Replacement of the Seal Oil System with a streamlined Point I/O distribution panel and PowerFlex 525 drives.
2nd Floor:
A total "gut and replace" of the area with a new enclosure. The team replaced multiple, bulky 1771-series racks with high-density Point I/O, new Mettler-Toledo IND360 scale indicators, and a modern PanelView Plus7 HMI for superior operator visibility.
Design, fabrication, and installation of an entirely new carbon black feeder panel to house replacement VFDs.
Design, fabrication, and installation of a new hydraulic unit I/O panel to facilitate connections to that independent system.
Physical Installation:
The physical execution was performed by Imperium’s sister company, ASBECO. Their team managed the removal of legacy hardware and the installation of custom-built, NEMA 12/Class 2/Div 2 rated enclosures, ensuring all work met stringent location requirements. The client used the project as an opportunity to migrate most of the system I/O from 120VAC to 24VDC with the design and installation teams ensuring successful conversion.
The client provided detailed specifications, existing system code, and participated in pre-set code reviews during the project. Their team played a pivotal role in system startup, easily handling commissioning responsibilities.
The Results
Unified Control: The facility moved from three processors to one, drastically reducing the complexity of the code and the number of failure points. The upgrade also provided the client with an opportunity to successfully migrate the MES-connection code to the latest Logix series processor.
Enhanced Communication: By migrating from RIO to Ethernet/IP, the client gained faster data refresh rates and easier integration with plant-wide networks. Further, the need for multiple steps between different older protocols was dramatically streamlined.
Future-Proof Hardware: The end-of-life PLC-5 was retired in favor of the latest Rockwell Automation Logix technology and aging PowerFlex 70 drives were replaced with modern PowerFlex 525 units.
Turnkey Execution: From control panel design and PLC logic consolidation to the physical mounting of I/O panels across three floors, the Imperium and ASBECO partnership delivered a seamless transition with zero "integration gaps."
This project stands as a testament to what can be achieved when a forward-thinking client and a high-caliber integration team align. The success of this complex, multi-level modernization was driven by the client's exceptional technical readiness and collaborative spirit; their detailed specifications and expert handling of system commissioning ensured a smooth transition into high-efficiency production. By leveraging the combined strengths of Imperium Technology Solutions and ASBECO, the client accessed a powerhouse partnership capable of bridging the gap between sophisticated control engineering and rugged physical installation. Together, the Imperium-ASBECO team proved to be a premier choice for complex system upgrades—transforming fragmented, legacy architecture into a streamlined, future-proof operation with unmatched precision.