Integration of legacy equipment into a standardized, data-driven line control environment
In FMCG production lines, different machines must operate in a consistent way and communicate effectively. One of our Romanian customers faced this with a legacy palletizer, still operational but limited in communication capabilities, that needed to be integrated into a standardized PackML-based line control system.
The objective was to upgrade the machine’s functional capabilities without replacing hardware, enabling it to communicate using PackTags while maintaining uninterrupted production. Contec delivered a smart integration approach that bridged the gap between legacy controls and modern automation standards, ensuring alignment with the broader system architecture.
Project Highlights:
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Integration of legacy palletizer into PackML-based line control system
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Implementation of PackTags communication without hardware replacement
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Development of custom PLC logic and middleware translation layer
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Standardization of machine states, alarms, and commands
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Deployment executed within limited downtime windows
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Staged testing and validation to ensure reliable data flow
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Improved interoperability and operational visibility
The challenge
Modernizing legacy equipment without disrupting ongoing production
The project centered around integrating an existing palletizer into a modern PackML-compliant environment. However, the machine’s legacy architecture lacked native support for structured communication protocols, making direct integration challenging.
At the same time, the palletizer remained a critical component in daily operations, meaning any extended downtime or major intervention was not an option. The solution had to enable standardized communication with upstream and downstream systems while preserving the integrity of the existing hardware.
Balancing these constraints required a precise and carefully orchestrated approach, one that would introduce modern functionality while minimizing risk, avoiding costly upgrades, and ensuring long-term maintainability.
Our approach
Bridging legacy systems with modern standards through smart integration
To overcome these challenges, Contec implemented a tailored integration strategy focused on adaptability and minimal disruption.
A middleware logic layer was introduced to translate existing machine signals into PackML-compliant PackTags, effectively creating a bridge between the legacy control system and the modern line architecture. Custom PLC programming was developed to manage machine states, modes, and transitions in accordance with PackML standards.
The integration was validated through staged testing, ensuring both functional accuracy and reliable data exchange across the system. Close collaboration with the line control team ensured alignment of communication protocols and message structures.
Deployment was carefully scheduled during planned downtime windows, allowing the upgrade to be implemented and commissioned with minimal impact on production.
