Engineering solution
Legacy PLC and SCADA migration replaces obsolete controllers and HMI/SCADA software with supported platforms while production keeps running. The work covers program conversion or rewrite, I/O and wiring strategy, staged cutover planning with rollback, functional testing, and as-built documentation — so the plant exits the project with a supportable system, not just newer hardware.
Every control platform eventually reaches the point where processors are unavailable, software runs only on unsupported operating systems, and each failure is a production gamble. Migration is inevitable; the only choice is whether it happens on a plan or during an outage.
We migrate systems in stages that respect production: converted and tested logic before cutover, I/O strategies that minimize rewiring, parallel or phased runs where the process allows, and a rollback path for every step.
Scope
Project process
Back up programs, verify drawings, and document the as-found system.
Convert or rewrite logic, rebuild HMI applications, and prepare hardware.
Simulate and test against documented machine behavior before touching production.
Execute within agreed windows with rollback ready at each stage.
Verify production performance and deliver as-built documentation.
| Approach | What it does | When it is right |
|---|---|---|
| Like-for-like conversion | Reproduces the existing logic on the new platform | Behaviour is correct and well understood, and downtime is the binding constraint |
| Re-architecture | Keeps the process but restructures code, tags and HMI | Logic is sound but unmaintainable, and your team has to own it afterwards |
| Rewrite | Re-specifies what the system should do | Existing behaviour is wrong, undocumented beyond recovery, or the process itself has changed |
We do not publish fixed prices: these are the factors that determine effort. A scoped proposal follows the technical fit review.
A migration is only as safe as the as-found picture it starts from. Where documentation is missing, recovering it is scoped as work in its own right rather than absorbed — a conversion performed against drawings that do not match the field moves the risk rather than removing it.
Last reviewed by Geek Engineering senior engineering review.
By moving risk off the critical path: logic is converted and tested offline first, cutovers are staged to fit outage windows, wiring strategies minimize field disturbance, and every stage has a rollback plan. The production system is only committed once the replacement has demonstrated equivalence.
It depends on the code's condition. Clean, well-structured logic can be converted and tidied. Decades of patched, undocumented logic is often faster and safer to rewrite against observed machine behavior. We assess this per system and recommend the lower-total-risk path.
Frequently, yes. Communication bridges and phased I/O handover let sections migrate one at a time on multi-system lines. Where the process cannot tolerate parallel operation, staged full cutovers with rollback are used instead.
As-built electrical drawings, documented and backed-up programs, an HMI/SCADA application under version control, and the test records from commissioning. The goal is that any qualified engineer can support the system after handover.
Start with the assessment and phased plan if you have not scoped the migration yet.
Options for aging machines: retrofit, remanufacture, or replace.
Full controls capability including troubleshooting and commissioning.
Describe your equipment, objectives, timeline, and constraints. We will confirm whether this solution fits — and say so plainly if it does not.
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