Legacy System Upgrades
& Control System Modernization
Secure, phased upgrades for legacy PLC, SCADA, and industrial automation—seamless integration, minimal downtime, maximum future-readiness.
Why Upgrade Legacy Automation Systems?
Many manufacturers, processors, and utilities in Australia are still running essential plant operations on aging, unsupported PLCs, SCADA systems, or obsolete HMI panels. These legacy control systems pose a real threat to safety, compliance, and business continuity, and expose you to:
Increased downtime and unplanned breakdowns
Difficulty sourcing spare parts for outdated hardware
Security risks and lack of modern cybersecurity features
Incompatibility with Industry 4.0, MES, and real-time analytics
Proven Technology in Action
The Crossmuller Solution
Every upgrade begins with a comprehensive site and risk audit by our experienced engineers. We then develop a step-by-step modernization roadmap designed for your plant’s needs and schedule.
Key steps include:
Legacy System Audit: Review of all PLCs, SCADA, HMI, networking, and control panels in use
Upgrade Planning: Phased migration plan to ensure continuous production and compliance
Hardware & Software Modernization: Installation and commissioning of new PLCs, SCADA, and industrial networking, with best-fit platforms such as Siemens, Rockwell, Wonderware, or Ignition
Integration: Seamless connectivity with existing field devices, drives, sensors, and higher-level MES/ERP systems
Testing & Training: Full system validation, site acceptance testing, and operator training for trouble-free go-live
Real Results You Can Benchmark
Crossmuller has delivered successful legacy automation upgrades for:
Food & beverage plants: Modernizing end-of-life PLC and SCADA systems to boost compliance and reliability.
Timber & building materials facilities: Upgrading legacy HMIs and implementing new control panels for future-proof operation.
Advanced manufacturing: Transitioning outdated control hardware to secure, networked solutions with full system documentation.
Benefits of a Crossmuller Legacy Upgrade
Minimal Downtime
Phased upgrades and staged commissioning keep your lines running
Regulatory Compliance
Meet Australian safety, cybersecurity, and traceability requirements.
Reduced Risk
Remove obsolete technology and improve disaster recovery options.
Data-Driven Operations
Enable advanced analytics, MES, and Industry 4.0 integration.
Long-Term Support
Full documentation, training, and future service available.
why CROSSMULLER?
Crossmuller delivers tailored legacy system upgrades, replacing end-of-life automation and seamlessly integrating new control technology—without interrupting your operations.
Frequently Asked Questions
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Taking the Next Step
Don’t wait for an unplanned outage or failed audit to upgrade your critical automation.
Contact Crossmuller today for a legacy system audit and tailored upgrade plan—built around your budget, timeline, and compliance needs.
- Phone: 1300 300 540
- Email: sales@crossmuller.com.au
Crossmuller acknowledges the Traditional Owners of the lands across Australia as the continuing custodians of Country and Culture. We pay our respect to First Nations peoples and their Elders, past and present.
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