Project NameRetrofit & Upgrade Solutions - Multiple Plants
Case Study: Retrofit & Upgrades
Control System Retrofit & Legacy Automation Upgrades - PLC, HMI, SCADA & Panel Modernisation
Modernising legacy PLC, HMI, and SCADA systems across pharmaceutical, chemical, and industrial plants - with minimal production downtime and full documentation for validation and compliance.
Project Overview
Project Information
Modernising legacy automation systems is essential for ensuring long-term reliability, regulatory compliance, and operational performance.
Hive Automation provides comprehensive retrofit and upgrade solutions for obsolete or aging control systems across pharmaceutical, chemical, and industrial plants - replacing outdated PLCs, HMIs, SCADA systems, and control panels with current automation platforms while preserving critical process knowledge and minimising production downtime.
Our retrofit approach is phased and planned around your maintenance schedule, so you are never forced into an unplanned full-plant shutdown to upgrade.
Project Details
Project Delivery Snapshot
Completion DateOngoing - 2017 to present
Scope of WorkPLC Migration | HMI/SCADA Upgrade | Panel Revamp | Software Conversion | FAT/SAT | Validation Support
LocationIndia (pan-India site commissioning)
System Architecture
Technical Architecture
Migration paths supported include Siemens S5 to S7-1500 in TIA Portal, S7-300 to S7-1500, and legacy Mitsubishi, ABB, or Rockwell systems to Siemens S7-1500 platforms.
HMI replacement paths include obsolete operator panels to modern Siemens TP and KTP series terminals for improved usability and long-term supportability.
SCADA replacement paths include legacy WinCC classic or third-party SCADA to current WinCC Unified or WinCC V7+ with updated documentation, security, and audit capabilities.
Delivery Scope
Scope of Work & Key Deliverables
- PLC & CPU Upgrades - hardware replacement from Siemens S5 or S7-300 to S7-1500, I/O rewiring, and TIA Portal code migration
- HMI & SCADA Upgrades - replacement of obsolete terminals with modern, 21 CFR Part 11-compliant Siemens HMI or WinCC SCADA
- Control Panel Revamp - refurbishment or full replacement of electrical panels including wiring, I/O modules, power distribution, and field termination
- Software Conversion - redevelopment of old ladder logic, SCADA graphics, and recipes into current TIA Portal and WinCC formats with optimised performance
- Documentation & Validation Support - complete updated documentation, FAT and SAT protocols, and support for validation and regulatory compliance audit readiness
Project Impact
Challenge & Outcome
Challenge
Retrofit projects require preserving critical process knowledge while replacing obsolete hardware and software under tight shutdown windows. The biggest challenge is minimising production downtime while ensuring migrated logic, updated panels, and replacement SCADA or HMI systems are fully validated before cutover.
Outcome / Result
Hive Automation continues to deliver phased retrofit and upgrade projects across pharmaceutical, chemical, and industrial plants - helping clients move from unsupported legacy automation to modern Siemens-based control systems with current documentation, validation support, and improved long-term maintainability.
Process Coverage
Processes Automated
- Process skids and batch systems including reactors, vessels, and utilities running on obsolete PLC hardware.
- Pharmaceutical equipment including reactors, sterilizers, DPT, filling and sealing, vessels, washers, and AHU or HVAC systems.
- Utility systems such as AHU, WFI, Pure Steam, HVAC, boiler, and water treatment systems requiring modern automation platforms.
- Packaging, conveying, and dosing systems with unsupported legacy machine controllers needing hardware and software replacement.
- Older SCADA and HMI interfaces including Windows XP and Windows 7 era SCADA systems and obsolete panel HMIs needing secure modern replacements.
- Structured retrofit execution from on-site audit and upgrade roadmap through cutover, commissioning, and as-built documentation handover.
Our Clients
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Frequently Asked Questions
Retrofit & Upgrades Automation Questions, Answered
Siemens announced end-of-sale for S7-300 hardware and its replacement by S7-1500. While some S7-300 products remain available, the platform is in its lifecycle end phase - spare parts availability is declining, and S7-1500 with TIA Portal is the recommended migration target. Planning your retrofit now avoids an emergency replacement later.
Ready to Transform Your Industrial Operations?
Partner with Hive Automation for Reliable Automation Support
Is your plant running on unsupported Siemens S5, S7-300, or other obsolete hardware? We plan and execute phased retrofit projects that minimise downtime and deliver a fully documented, compliance-ready modern control system. Contact us for a free risk assessment.