PLC Upgrade Services

PLC upgrades: Upgrading your unsupported and obsolete PLC systems

Many companies operate with ageing PLC systems, which can create operational risks, inefficiencies, and costly downtime. Whether your PLC hardware is obsolete, you need more processing power, or you want to standardise systems across multiple sites, a well-planned software upgrade is essential.

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Upgrading a PLC is more than a hardware swap

Upgrading a PLC is not just about replacing hardware—it’s about ensuring the software structure is optimised, future-proofed, and aligned with Industry 4.0. Whilst many PLC vendors have migration tools to help you move from an old PLC to their current model, we prefer to take an objective view and use the upgrade as an opportunity to remove unused program elements and ensure that all new code is well commented. Simple migration might be cheaper, but in the long run could become harder to support… do it once, do it right!

Our experienced PLC engineering team provide:

– Upgrades from obsolete PLCs to modern equivalents
– Cross-brand software conversions and migrations
– Integration with cloud-based SCADA and smart factory networks
– Functional safety upgrades to keep pace with latest machinery legislation
– Fully documented, structured, and scalable PLC code

Simple migration might be cheaper, but in the long run could become harder to support… do it once, do it right!

Rockwell and Siemens PLC upgrade specialists

As a Rockwell Gold Partner and a Siemens Integrator Partner, we are perfectly placed to upgrade your PLCs to the right platform for your site. We can also migrate from one obsolete PLC to a different brand to match your company standard and have experience with the other main PLC vendors of Mitsubishi, Beckhoff and Schneider Electric.

Upgrading obsolete PLCs without source code

Where software source code and PLC project files are unavailable, inControl’s team of experienced engineers can reverse engineer the process, working with your operators to understand how it runs, then migrate your at-risk control system to a new PLC platform.

Smooth, cost-effective PLC and DCS migration

Our PLC / DCS programming makes transitions smooth and cost-effective, so your new system is easy to maintain, modify and expand as your business evolves.

With inControl, you receive well-structured, scalable, and fully documented PLC code. Ensuring minimal disruption during the upgrade process and future flexibility for modifications.

Use your PLC upgrade to enable digital transformation

A PLC software upgrade can serve as an opportunity to connect machines into a smart factory network, enhancing data accessibility, automation, and predictive analytics.

What lurks behind those cabinet doors? If you don’t know, maybe it’s time for an upgrade?

Why choose inControl for your PLC upgrade?

– Fully scalable solutions aligned with Industry 4.0 and digital transformation strategies

– Rockwell Gold Partner and Siemens Integrator Partner

– Expert PLC software engineers with extensive industry experience

– Comprehensive software documentation to assist future modifications

– Ownership of your PLC source code and project files passes to you on completion

Running an obsolete PLC? Contact inControl today to discuss your PLC / DCS upgrade journey.

inControl dedicated to every PLC system we help build for clients

More on the importance of maintaining your PLC system from inControl.co.uk

Understanding the importance of specifications in PLC Programming

Delve into the crucial specification steps that inControl Systems take in both upgrade projects and new projects alike .

Achieving digital transformation and PLC upgrades at the same time

Discover how to tackle control system obsolescence and kickstart digital transformation — even while your plant keeps running.

And what about upgrading your SCADA system?

For some customers, upgrading their PLC systems is often only half of the challenge if their PLCs are connected to an equally old SCADA system.

A new PLC system could mean avoiding lengthy and costly unplanned downtime…

Best practice PLC upgrades and program changes

As industrial automation evolves, PLC software maintenance and security play an increasingly vital role in long-term efficiency and operational stability. Here are some key considerations:

Keep your PLC software files secure – Proper backups and version control can prevent costly downtime and simplify future upgrades.

Work with trusted system integrators – Ensure your control system provider delivers fully documented, structured, and well-commented code to support long-term modifications and troubleshooting.

Click here to download the Automation Software Support Recommendations for End-Users White Paper