The PLC Migration: Modernizing industrial Automation

December 29, 2023 by
Pedro Silva dasdadsad

In the world of industrial automation, Programmable Logic Controllers (PLCs) are the core of many operations. However, with the rapid advancement of technology, older PLCs can become obsolete, leading to the need to migrate to more modern systems. In this blog, we will explore what PLC migration entails, why it is important, and how it can benefit companies.

What is PLC migration?

PLC migration is the process of replacing an older or obsolete PLC with a new and updated one. This involves transferring control logic, programming, user interfaces, and, in some cases, even hardware to ensure continuous operation of automation systems.

Reasons to consider PLC migration

  1. Obsolescence: Older PLCs may become incompatible with spare parts, increasing the risk of unplanned downtime in case of failure.
  2. Performance Improvement: Modern PLCs often offer superior performance in terms of processing speed and data storage capacity.
  3. Increased Efficiency: New PLC technologies can optimize processes, reducing operating costs and improving production efficiency.
  4. Easier Maintenance: More modern systems often require less maintenance and provide advanced diagnostics for easier issue identification.
  5. Regulatory Compliance: Migrating to current PLCs can help comply with the latest industrial regulations and standards.

Key steps

  1. Evaluation: It begins with a comprehensive assessment of existing systems to determine the need for migration and the goals to be achieved.
  2. Planning: Develop a detailed plan that includes the selection of the new PLC, the transfer of control logic and programming, and staff training.
  3. Implementation: Carry out the migration following the established plan, ensuring to minimize downtime as much as possible.
  4. Testing and Validation: Conduct thorough tests to ensure the new PLC operates correctly and meets performance requirements.
  5. Training: Provide adequate training to operators and technicians to ensure they understand and are comfortable working with the new PLC.
  6. Documentation: Maintain detailed records of the entire migration process and the new PLC configuration.


  1. Extended Longevity: Migration extends the lifespan of automation systems, avoiding costly complete upgrades.
  2. Productivity Improvement: Modern PLCs allow better control and optimization of processes, leading to increased productivity.
  3. Enhanced Reliability: Component obsolescence is a major cause of system failures, and migration resolves this issue.
  4. Regulatory Compliance: Updating to newer PLCs often helps comply with current and future regulations.
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