Process Modernization: IESA Supports a Major Tire Manufacturer
Modernizing without disrupting production: a key industrial challenge
In today’s industrial environment, performance and production continuity are critical. Modernizing existing equipment has become a strategic priority—but also a major challenge.
How can manufacturers upgrade obsolete systems while minimizing production downtime and operational risks?
IESA is currently supporting a major player in the tire manufacturing industry in a high-value industrial retrofit project.
A modernization project at the heart of production processes
IESA’s scope focuses on two key production systems.
These critical assets require technological upgrades to ensure long-term reliability and maintain operational efficiency.
The goal: extend equipment lifespan while aligning with current industrial standards.
PLC migration and adaptation of existing programs
At the core of this project, IESA teams are delivering advanced industrial automation services, with a pragmatic approach:
👉 preserve what works, upgrade what’s necessary.
A controlled automation system conversion
The project includes:
- Adapting existing PLC programs to a new environment
- Migrating legacy Rockwell SLC500 PLCs to modern CompactLogix platforms
- Converting programs in compliance with client standards
This methodology ensures a secure technological transition, while leveraging the existing functional logic of the systems.
Industrial simulation and testing: ensuring reliability at every stage
To guarantee performance and reliability, IESA relies on its expertise in industrial simulation.
Validation before deployment
All developments go through:
- Simulation-based testing
- Functional sequence validation
- Global system behavior checks
In addition, workshop testing is conducted on:
- Motors
- Drives
- Control systems
This approach helps anticipate issues early and significantly reduces risks during on-site commissioning.
Equipment upgrades as a driver for long-term performance
Beyond PLC migration, the project also includes drive modernization:
- Replacement of DIGIDRIVE with M400
- Upgrade from UNIDRIVE SP to M702
These improvements contribute to:
- Enhanced energy efficiency
- Increased system reliability
- Easier maintenance and scalability
Industrial retrofit: a strategic alternative to full replacement
This project highlights the key benefits of industrial retrofit:
- Reduced capital expenditure
- Minimal production downtime
- Preservation of existing assets
- Compliance with modern standards
For manufacturers, retrofit is a smart and cost-effective strategy to modernize operations without full system replacement.
IESA, your partner in industrial automation projects
With strong expertise in:
- Industrial automation
- Electrical engineering
- Industrial simulation
IESA supports clients in complex modernization projects, delivering solutions tailored to real-world industrial constraints.
Conclusion: what are the key challenges of industrial retrofit?
Modernizing existing equipment raises several challenges: technology compatibility, production continuity, obsolescence management…
👉 In your opinion, what are the biggest challenges when upgrading legacy industrial systems?