Modernization of critical raw material handling system through phased migration to Rockwell PlantPAx architecture
A major food production facility in Belgium, required the modernization of its Raw Materials (RM) installation, a critical system responsible for storage, distribution, and unloading of ingredients feeding six production lines.
The existing automation setup relied on obsolete Rockwell PLC5 systems combined with a Honeywell TDC3000 platform, creating increasing risks in terms of reliability, maintainability, and system integration.
Contec delivered automation and E&I services to migrate the first phase of this installation to a modern Rockwell ControlLogix platform, while preparing the foundation for a full transition to PlantPAx P5. The project was executed during a highly constrained 3-day plant shutdown, requiring precise planning, risk mitigation, and seamless execution without impacting production continuity.
Project Highlights:
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Migration of critical raw materials installation feeding 6 production lines
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Replacement of obsolete Rockwell PLC5 systems with ControlLogix
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Integration with existing Honeywell TDC3000 system via temporary gateway
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Full E&I engineering package including demolition, construction, and network design
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Execution during a 3-day shutdown without production losses
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Preparation of PlantPAx P5 architecture for future migration phases
Migration of critical raw materials installation feeding 6 production lines
The challenge
Executing a high-risk migration under strict time constraints
The Raw Materials installation represents a central system supplying all six production lines, meaning that any downtime has a direct and immediate impact on the plant’s overall production output. The existing automation setup combined Rockwell PLC5 systems for digital control with a Honeywell TDC3000 platform handling analog processes, both interconnected through serial communication. This hybrid and obsolete architecture introduced significant complexity for any migration activity.
The project required the complete replacement of outdated PLC5 hardware across both the Raw Materials and Raw Materials Unload installations, while maintaining seamless integration with the still-active TDC3000 system. All electrical and automation migration activities had to be executed within a strict three-day shutdown window, leaving no margin for delays. At the same time, ensuring a smooth and immediate restart of all six production lines was critical, as any disruption would result in substantial production losses. Managing installation risks, commissioning uncertainties, and system integration challenges within such a constrained timeframe made this a highly complex and high-risk project.
Our approach
Ensuring a controlled migration through detailed preparation and execution
To manage these constraints, Contec approached the project with a strong focus on preparation, structure, and risk mitigation. The engineering scope covered the full lifecycle of the migration, starting with detailed demolition planning and continuing with construction drawings for new PLC cabinets and Flex I/O panels. A new Ethernet/IP network architecture was designed to support the modernized control environment, alongside clear work instructions to guide on-site execution.
On the automation side, the existing PLC5 logic was converted to the ControlLogix platform using Rockwell tools, then carefully validated and optimized. To ensure continuity during the transition, a temporary gateway PLC was implemented, enabling communication between the new ControlLogix system and the existing TDC3000 platform.
In parallel, the new setup was designed with the future in mind. A PlantPAx P5-ready architecture was established, creating a scalable foundation for the next phases of the migration program.
This structured and well-prepared approach allowed the team to execute the migration in a controlled manner, minimizing risks and ensuring a smooth transition within the limited shutdown window.
