Modernizing for profitability: What a PLC upgrade can do for you

While built to last, some of the earliest programmable logic controllers (PLCs) from the 1970s still require modern upgrades to improve reliability. Modernizing this essential technology not only minimizes the risk of failure and downtime but also reduces the likelihood of future maintenance and potential replacement costs.

In this post, part of the EcoFit for PLC blog series, I’ll show how plant operators can unlock new levels of efficiency, profitability, and operational excellence by upgrading PLCs before an unplanned system failure. Doing so could yield substantial benefits, saving time and money, as well as immediate production and performance improvements that lower the total cost of ownership (TCO).

Modern capabilities transform maturing assets

Boosting plant profitability and the operational efficiency of maturing assets are crucial objectives for a modern industrial facility, especially as operations continue to transform with advanced digital-native solutions.

Migrating decades-old PLCs is a proactive step toward mitigating operational risks, such as battery failure (modern programmable automation controllers, PACs, no longer use them) and cyber vulnerabilities.

Today’s PLC and PAC technologies deliver a higher return on investment (ROI) by increasing productivity. Upgrading to a more powerful controller, for example, might increase production value by monitoring quality control variables in real time or by reducing time-to-market. A controller with improved connectivity might also reduce energy costs by enabling real-time monitoring or reduce material costs by improved feed control.

Control system upgrades will undoubtedly improve plant operators’ ability to diagnose and time to repair, with remote maintenance now a possibility—and a new normal.

Reducing downtime with modern technological advances

In addition to having many more productive years ahead, modern controllers reduce risk through better diagnostics, connectivity, and visibility, making it increasingly likely that operators can fix issues before they become critical.

Today’s PLCs offer predictive diagnostics for one of the most susceptible components of this system: its power supply. This helps anticipate and avoid downtime. Other critical improvements include enhanced availability and connectivity without compromising cybersecurity.

Bringing this to bear, our Modicon PAC platforms seamlessly integrate modern technologies to enhance system performance, ensuring more secure, consistent uptime.

The Modicon M580 control platform provides detailed, proactive diagnostics and health monitoring for its power supplies, including redundant configurations, enabling condition-based and preventive logic at the system level.

When we talk about cybersecurity, attention is focused on the Cyber ​​Resilience Act (CRA), a European Union (EU) regulation that mandates cybersecurity requirements for products with digital elements (e.g., hardware and software). The CRA helps ensure products are secure from design through use and maintenance, protecting consumers and businesses against cyberattacks, with vulnerability reporting obligations and full compliance required by 2027.

Modicon M580 includes cybersecurity features designed for industrial environments and aligned with IEC 62443 standards, such as secure communications (TLS‑based encryption), role‑based access control, and user authentication to protect configuration and operations.

The platform provides embedded firewall functionality, network segmentation, and secure firmware signing to prevent unauthorized code execution. Native support for secure protocols such as Modbus TCP Security enhances data integrity and confidentiality. Integrated security monitoring and compatibility with EcoStruxure cybersecurity tools help organizations implement a defense‑in‑depth approach and support regulatory compliance for critical infrastructure and industrial automation systems.

Optimizing maintenance costs

Control system migration offers plant operators the opportunity to address issues while placing greater emphasis on lifecycle costs, resulting in a lower total cost of ownership (TCO).

Most companies find that control system migrations pay for themselves within two years of investment, with value-added from both immediate production gains and longer-term, scalable advantages, such as improved spare inventory.

Smarter systems offer a competitive advantage

Operations and maintenance are where some of the most important breakthroughs are taking shape to simplify and improve performance. Upgrading from an older-generation PLC to a more modern PLC or PAC can significantly reduce operational downtime, potentially leading to substantial cost savings through reduced maintenance over time.

For instance, one of Schneider’s customers, a large petroleum pipeline, upgraded from an obsolete Symax PLC to Schneider Electric’s M580, bringing it into the future.

With minimal production downtime, hardware was replaced, the network was modernized, and SCADA was enhanced.

The result? One system is installed per week with seamless integration and improved reliability. Performance skyrocketed, and operations became more resilient and efficient.

This is the power of a smart PLC upgrade: greater control and visibility.

When you invest in new industrial automation assets, the journey doesn’t end at commissioning; it’s only the beginning. To keep your operations running reliably, efficiently, and confidently, Schneider Electric offers comprehensive lifecycle support through its Advantage Service Plans.

Designed specifically for EcoStruxure and Modicon platforms, these modular annual service contracts ensure you always have the right level of expertise, responsiveness, and flexibility to maintain peak system performance.

Two tiers, tailored for your needs

Schneider Electric simplifies your support experience with two pre-packaged tiers—each designed to meet different maintenance strategies and operational priorities, with optional customizable services.

1. Essential Tier — Remote + Software Updates
   • Ideal for teams that prefer self-management but need expert assistance when challenges arise.
2. Advanced Tier — Remote Support + Software Updates + Onsite Support
   Perfect for operations where uptime is critical and rapid onsite response is essential.

Download the full white paper focused on demonstrating ROI in the context of present and future profitability.

About the author

Fernando Capelari, PLC Modernization Offer Manager

With over 25 years of experience in Industrial Automation and business development, Fernando has held a series of strategic roles across Schneider Electric Americas operations. Currently serving as the Global Offer Manager for PLC Modernization solutions at Schneider Electric, he has previously driven growth initiatives as the Americas Business Development Manager for EcoStruxure Process Expert (Hybrid DCS) and Process Automation solutions in the MMM sector. Fernando’s career spans roles in product management, business development, strategic marketing, and the integration of multiple companies acquired by Schneider Electric over the past few years, showcasing a strong track record in developing and executing innovative automation solutions across diverse industries.