Industrial Automation Revamping: IESA Modernizes a Polymer Production Skid
Modernizing an existing industrial system involves much more than simply replacing one PLC with another. Industrial automation revamping requires rethinking the control system architecture, integrating process and equipment changes, and ensuring that the entire system operates consistently before being returned to production.
This is exactly the challenge behind a new project recently awarded to IESA Automation for the tire manufacturing industry.
The project involves the automation revamping of a polymer production skid, including the migration from a Siemens architecture to a Rockwell Automation solution, the complete redevelopment of the PLC program, and the integration of new process control functionalities.
Automation revamping that goes beyond a PLC migration
In an existing industrial environment, a technology migration must take into account all interactions between the control system, process equipment, and production requirements.
For this project, IESA’s teams are handling the migration from Siemens to Rockwell Automation.
However, the scope goes far beyond replacing the existing hardware. Changes made to the skid also have a direct impact on the control program and require a comprehensive redesign of the automation system.
The project includes:
- migration of the automation architecture from Siemens to Rockwell Automation;
- complete redevelopment of the PLC program;
- implementation according to the PlantPAx® DCS standard;
- use of a ControlLogix® P-Controller;
- integration of a FactoryTalk® Batch control system based on the ISA-88 standard;
- implementation of FactoryTalk® Optix™ for visualization;
- integration of hardware modifications to the skid and their impact on the control program;
- hot testing of the system;
- and on-site commissioning in Clermont-Ferrand, France.
PlantPAx and ControlLogix at the heart of the new architecture
The PLC program redevelopment is based on the Rockwell Automation PlantPAx® DCS standard and a ControlLogix® P-Controller.
This architecture provides a control environment designed to meet the requirements of industrial processes while enabling the automation program to be structured according to the standards selected for the installation.
For IESA, the challenge is to reproduce all required existing functions while simultaneously integrating modifications to the skid and the new functionalities expected from the upgraded system.
This stage directly draws on our teams’ expertise in PLC programming, process control, and industrial automation system integration.
FactoryTalk Batch for recipe and sequence management
One of the project’s key developments is the addition of a FactoryTalk® Batch control system.
In a polymer production process, managing the different stages of production is a critical part of process control.
FactoryTalk Batch enables recipes and production sequences to be organized and executed using a structured approach based on ISA-88, the international standard for batch process control.
Integrating this functionality therefore represents a significant upgrade to the skid. The project is not simply about migrating the existing automation system, but also about enhancing it with new batch process control capabilities.
New visualization with FactoryTalk Optix
The automation revamping also includes the implementation of FactoryTalk® Optix™ for visualization.
The HMI provides the interface between operators and the industrial process. Its design must provide operators with the information they need to monitor the installation and interact efficiently with the different functions of the control system.
The implementation of the new visualization system is therefore an integral part of the overall automation redesign carried out by IESA.
From engineering to hot testing
Industrial automation revamping does not end once the PLC programming is complete.
Before the upgraded installation is returned to production, the different functions must be tested under conditions that are as representative as possible of actual operation.
IESA’s teams will perform hot testing of the skid to validate the behavior of the control system with the process.
This testing phase will verify, among other things:
- execution of automated sequences;
- interactions between the automation system and process equipment;
- integration of hardware modifications;
- operation of the batch control system;
- HMI functions and operator interactions.
The project will then continue with an on-site intervention by IESA’s teams in Clermont-Ferrand, France, to support the commissioning of the new architecture.
A project carried out in partnership with Rockwell Automation
For this project, IESA is working in partnership with Rockwell Automation, particularly for hardware and technical support.
This collaboration supports the implementation of the Rockwell ecosystem selected for the project: ControlLogix®, PlantPAx®, FactoryTalk® Batch, and FactoryTalk® Optix™.
Combined with IESA’s expertise in system integration and PLC programming, this partnership helps deliver a solution aligned with the technical requirements and constraints of the existing installation.
IESA's expertise in control system modernization
This new project for the tire manufacturing industry demonstrates IESA’s ability to work on existing industrial installations requiring both a technology migration and a functional upgrade.
With expertise in automation, visualization, electrical engineering, industrial IT, and process simulation, IESA supports manufacturers throughout their modernization projects—from assessing the existing installation and defining the new architecture to programming, integration, testing, and commissioning.
This comprehensive approach is particularly important for industrial automation revamping projects, where the new solution must integrate seamlessly into an existing production environment while meeting evolving process requirements.