Corrugated Equipment Controls Modernization
Aging controls → New PLC/HMI panel → Existing machine integration
Controls and Electrical Panel Modernization
- Industry
- Corrugated / Packaging
- Equipment
- Corrugated manufacturing equipment
- Project
- Controls & Electrical Panel Modernization
- Modernization Scope
- Control panel · PLC · HMI
- Approach
- Replace the control layer; integrate what still works
- 01
The Machine
An aging control system on equipment that could keep running.
Meray was brought in to evaluate aging controls on corrugated manufacturing equipment. The equipment itself could continue serving the operation — the existing controls were what required a substantial upgrade.
Rather than approaching the project as a complete machine replacement, Meray set out to modernize the control layer while integrating the new controls with the equipment that could remain.
- 02
The Problem
Modernize the controls without redesigning the whole machine.
Much of the machine's field infrastructure could remain in service. The existing system consisted primarily of discrete signals, several analog signals, machine counters, and existing field wiring and devices.
The challenge was therefore not to redesign the entire machine. It was to replace and modernize the control layer, then successfully integrate the new controls with the equipment that could stay.
- Discrete inputs
- Discrete outputs
- Several analog signals
- Machine counters
- Existing machine devices and field wiring
- 03
What We Kept
The functioning machine and its field infrastructure.
Instead of replacing functioning portions of the machine unnecessarily, Meray identified what could remain in service and built the new control architecture around it.
- The mechanical equipment
- Existing sensors and machine devices
- Existing field wiring
- Existing discrete and analog I/O
- 04
What We Modernized
A new control panel built around a modern PLC and HMI.
Meray designed and installed a new control panel built around a modern PLC and HMI, then connected the new control architecture to the machine's existing field systems.
- Evaluation of the existing control system
- New control-panel design
- New PLC
- New HMI
- Updated controls architecture and programming
- 05
How We Integrated It
New controls, connected to the existing machine.
The new PLC/HMI control system was integrated with the machine's existing discrete inputs and outputs, analog signals, counters, and machine systems — so the equipment that could remain kept doing its job through a modern control layer.
- Integration of existing discrete inputs and outputs
- Integration of analog signals
- Integration of machine counters
- Connection to existing machine systems
- 06
Testing & Commissioning
Verified before the modernization was called complete.
Meray tested the connected inputs, outputs, analog signals, counters and machine functions to verify operation, then commissioned the system and confirmed the machine ran through its modernized controls.
- Controls programming
- System testing
- Commissioning and functional verification
- 07
Result
The existing machine, operating through modernized controls.
The machine was successfully integrated with the newly designed PLC/HMI control system. Meray verified the connected inputs, outputs, analog signals, counters and machine functions before completing the modernization — so a machine that still had value continued serving the operation on a modern control platform.
The engineering decision: what to replace, and what to keep.
Existing Machine
Mechanical equipment · Existing sensors / devices · Existing field wiring · Existing I/O
Meray Modernization
New control panel · New PLC · New HMI · Updated controls architecture · New programming
Commissioned System
Existing machine operating through modernized controls
Have an aging machine you’re considering replacing?
Before you replace it, let Meray evaluate it.