Vardhman Acrylics Limited – Baling Press Modernization
End-to-End PLC Migration & Panel Retrofit
The Challenge:
Vardhman Acrylic undertook a planned modernization initiative to replace its legacy Siemens S5 PLC systems with the latest Siemens S7-1500 platform during the annual plant shutdown. The shutdown window was limited to four days, during which four critical PLC systems of the non-woven material baling press machine—the baler, Tow Line 1, Tow Line 2, and the conveyor system—were taken up for upgrade. The scope involved complete panel revamping, including removal of all obsolete components and installation of new S7-1500 PLCs along with ET200SP I/O systems. The project demanded a high level of precision due to the presence of a critical hydraulic system, multiple interlocks, and complex control logic, where even a small error could have resulted in serious damage to heavy equipment. Adding to the challenge, strict safety norms and limited manpower availability allowed work to be carried out only during day hours. Given these constraints, the project required a dependable and technically competent partner to ensure the upgrade was executed safely, accurately, and within the tight shutdown schedule.
The Solution:
Taking the defined constraints as a challenge, Velox Automation carried out thorough pre-shutdown planning, logic validation, and execution sequencing. The old Siemens S5 PLCs were replaced with new Siemens S7-1500 PLCs and ET200SP I/O systems. The panels were completely redone, and old hardware was taken out. The complex hydraulic logic and critical interlocks were carefully migrated and tested to ensure safe and reliable equipment operation. Despite a planned four-day shutdown and work being permitted only during day hours, the entire retrofit, including testing and production trials, was completed two days ahead of schedule. The systems were commissioned smoothly, enabling a safe and stable production start-up. The successful early completion and strict focus on safety earned strong appreciation from the customer and reinforced their confidence in Velox Automation’s capabilities.
Why Velox Solutions Makes Sense
For the client:
The customer successfully migrated from the legacy Siemens S5 platform to the latest Siemens S7-1500 PLCs without any compromise on safety, quality, or system reliability. All four critical PLC systems were fully retrofitted within a much shorter shutdown period, helping minimize production losses. The upgraded control system now ensures stable, safe, and reliable operation of the critical hydraulic process, while the early completion restored customer confidence and delivered clear operational value.
For the environment:
Right first-time execution minimized rework, reducing energy use and resource wastage during the shutdown. The control system upgrade supported more sustainable and responsible manufacturing practices.