Control System Replacements -

Control System Replacements
by Crossmuller

Replace outdated or obsolete PLCs, SCADA, and control panels with modern automation technology—minimizing downtime and unlocking the full potential of your operations.

Why Replace Your Control System?

Aging or unsupported control systems create hidden risks and limit your operational growth. Many factories and processing plants still rely on obsolete PLCs, legacy SCADA, and outdated control panels—leading to:

Increased breakdowns and unplanned downtime
Difficulty sourcing parts and technical support
Cybersecurity vulnerabilities and compliance risks
Incompatibility with modern MES, IoT, and analytics platforms

Proven Technology in Action

The Crossmuller Solution

Every project begins with a detailed audit of your current automation, controls, and networking. Our team then engineers a step-by-step replacement plan tailored for your schedule and production needs.

Our control system replacement services include:

Legacy PLC and SCADA replacement with leading-edge technology (Siemens, Rockwell, Wonderware, Ignition, etc.)
Control panel design, fabrication, and wiring to Australian standards
Full migration and integration with drives, sensors, MES, and ERP systems
Phased cutover to minimize downtime and production risk
Comprehensive system validation, operator training, and documentation

Real Results You Can Benchmark

Crossmuller replaced a legacy PLC-5 and outdated HMI system with a modern Logix5000 and FactoryTalk View Studio platform. Nearly 1,000 I/O points were migrated, control logic was updated, and the project achieved a seamless switchover during a short shutdown.

Project Highlights

One of Australia’s leading plaster board manufacturers has once again contracted Crossmuller to complete the next stage of their ongoing plant technology upgrades
Conversion of the Existing PLC5 Code into the Logix5000 Format
Migrating Conductor NT Screens to Factory Talk View Studio
Integration of Redundant Instrumentation Control into the PLC.

Benefits of Modern Control System Replacement

Enhanced reliability, fewer failures, and lower maintenance costs

Support for Industry 4.0, data analytics, and MES integration

Improved safety, compliance, and cybersecurity

Future-proof automation built for easy expansion

Full documentation, training, and post-project support

why CROSSMULLER?

Crossmuller specializes in control system replacements that modernize your automation infrastructure for safer, more reliable, and data-driven operations—delivered with minimal disruption.

Frequently Asked Questions

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Taking the Next Step

Don’t let obsolete automation limit your business.
Contact Crossmuller today for a control system assessment and see how a modern replacement can unlock your plant’s true performance.