Industrial Controls Upgrades
Automation | Process | Motion | Building Management | Safety | Machine
At Rise Automation, we specialise in upgrading existing control systems often improving performance and reliability. Whether you require a full system overhaul or targeted upgrades to key components, our team is ready to deliver solutions that are reliable and robust. We collaborate closely with you to ensure each upgrade integrates seamlessly with your existing setup, providing improved functionality and longevity.
Electrical Drawings
Our electrical designers will review your existing drawings and create new schematics that incorporate all upgrade work ensuring your machine is ready to be maintained for the next phase of its operational life.
Software
Upgraded operating and diagnostic interfaces significantly increases machine usability by minimising the time needed to identify stoppages and providing access to historical performance supporting proactive maintenance.
Integration
Modern controllers allow for greater system integration, simplifying machine complexity while enhancing the reliability, durability, and overall robustness of the control system. reducing the risk of operational disruptions.
Before
After
When a servo system with an integrated PLC failed, we took the opportunity to modernise the entire control and operator interface. The solution involved replacing the obsolete unit with a Siemens S7‑1200F CPU paired with a CU250S Position Controller. This upgrade significantly improved the machine’s control precision and diagnostic capabilities, while also laying the groundwork for future expansion and integration. The S7‑1200F’s safety features enabled full monitoring of safety circuits and allowed isolation of the remaining variable frequency drives (VFDs) in line with current industry standards, ensuring both compliance and operational reliability.
Our blog explores the pros and cons of upgrading controls versus purchasing new machinery, offering guidance on how to make the best decision for your business. > Read
Technology we Support
Siemens Control Systems
Trusted across global industries for advanced PLC, HMI, and SCADA solutions, ideal for complex, high performance applications.
Retrofit & System Upgrades
Breathe new life into legacy machinery with modern controls, improving reliability, efficiency and data visibility.
EtherNet/IP
Developed by Rockwell Automation, this protocol enables real time control and device level communication, commonly used in Allen Bradley systems.
Omron Automation
Compact, flexible systems with excellent motion, safety, and vision capabilities, perfect for fast paced production environments.
SCADA & Remote Monitoring
Gain full control and visibility of your system, view diagnostics, trends, and alarms in real time from anywhere.
EtherCAT
An ultra fast, low latency Ethernet protocol ideal for motion control and time critical applications, popular in robotics, CNC systems, and high speed packaging lines.
Allen Bradley (Rockwell)
Heavy duty PLCs and intuitive HMIs, widely used in large scale manufacturing and process automation.
Servo & Motion Control
Achieve precise movement and synchronisation, essential for robotics, pick & place, labelling and packaging tasks.
Modbus (RTU & TCP/IP)
A simple, robust protocol for connecting industrial devices, ideal for SCADA systems, HMIs, and interfacing between third party equipment and control panels.
Mitsubishi Electric Controls
Reliable, cost effective systems with strong motion control, well suited to UK and European production standards.
Profinet
An industrial Ethernet standard developed by Siemens, offering fast, deterministic communication ideal for high speed automation and real time data exchange
CANopen
A reliable fieldbus used in embedded control systems and motion networks, often found in machinery where compact, distributed control is needed.
Custom PLC & HMI Programming
From basic control panels to full production line integration, we build bespoke systems around your process and equipment.
Profibus
A widely used fieldbus protocol for reliable serial communication between devices, ideal for connecting PLCs, sensors, actuators, and drives.
DeviceNet
A low cost network used mainly for sensor and actuator communication in Allen Bradley systems, supports easy integration in standard factory automation tasks.
FAQs
What is a PLC in industrial automation? A PLC (Programmable Logic Controller) is a rugged industrial computer used to control machinery, monitor inputs/outputs, and automate processes reliably in harsh environments.
What is an HMI and why is it important? An HMI (Human-Machine Interface) allows operators to interact with machines through touchscreens or panels, enabling real-time control, monitoring, and fault diagnostics.
What control systems do you supply for automated machinery? We supply custom-built control panels incorporating PLCs, HMIs, servo drives, VFDs, safety relays, and I/O modules — tailored for your specific automation application.
Do you offer turnkey PLC and HMI solutions? Yes. We design, build, program, and commission complete control systems, including bespoke PLC logic, HMI screens, and on-site integration.
What brands of PLC and HMI systems do you work with? We support major industrial automation brands including Siemens, Allen-Bradley (Rockwell), Mitsubishi, Omron, Schneider Electric, and more.
What is the role of a servo drive in automation? A servo drive controls the position, speed, and torque of servo motors, ensuring precise motion control for tasks like indexing, cutting, or positioning.
How do VFDs work in automation systems? VFDs (Variable Frequency Drives) control the speed of AC motors, improving energy efficiency and allowing dynamic adjustment based on load demand.
Can you retrofit existing machinery with new PLCs and HMIs? Absolutely. We specialise in PLC and HMI retrofits, upgrading outdated control systems to improve reliability, functionality, and connectivity.
What industries use PLC/HMI control systems? Industries include food and beverage, packaging, pharmaceuticals, automotive, material handling, water treatment, and general manufacturing.
Can you integrate safety systems into PLC panels? Yes. We implement integrated safety solutions including emergency stops, safety relays, light curtains, and monitored safety zones.
What types of automation tasks can PLCs control? PLCs manage tasks such as machine sequencing, motor control, conveyor automation, batching, filling, temperature regulation, and more.
What communication protocols do your systems support? We configure systems using Ethernet/IP, Modbus, Profinet, CANopen, Profibus, and other industrial protocols for seamless equipment integration.
Can you provide remote access to PLC and HMI systems? Yes. We offer remote connectivity options for diagnostics, updates, and monitoring via VPN or cloud-based solutions, enabling off-site support.
Do you offer control systems for multi-axis motion applications? Yes. We supply coordinated motion control solutions using PLCs, servo drives, and motion controllers for multi-axis machines like CNCs, gantries, and robotics.
How do you program your control systems? Our engineers program PLCs and HMIs using manufacturer-specific environments such as TIA Portal (Siemens), Studio 5000 (Rockwell), GX Works (Mitsubishi), and others.
Can your control panels operate in harsh or hygienic environments? Yes. We offer IP-rated, stainless steel, and ATEX-certified panels for environments requiring washdown, dust resistance, or explosion protection.
Do you provide documentation and electrical drawings? Yes. Every control system includes full documentation — wiring schematics, PLC/HMI backups, safety circuit details, and operator manuals.
Do you offer support and maintenance for your control systems? Yes. We offer on-site support, remote assistance, and service-level agreements to keep your automation system running reliably.
Conveyors
Cobot Palletising
Control Cabinets