PLC Modernization & Optimization
Modernize your Rockwell Automation and Siemens PLC infrastructure with custom engineering, optimization, and seamless integration into your existing systems.
- Platform-Specific Expertise: Deep experience with Rockwell Automation (CompactLogix, ControlLogix, GuardLogix) and Siemens (S7-1200, S7-1500, ET 200SP) controllers.
- Custom Engineering: Purpose-built PLC programs and applications tailored to your specific production requirements.
- System Optimization: Improving cycle times, memory utilization, and communication efficiency in existing programs.
- Modernization & Upgrades: Migrating legacy systems to current platforms while preserving operational continuity.
- Integration & Connectivity: Connecting PLCs seamlessly to SCADA, MES, data analytics, and enterprise systems.
- Ongoing Support: Continuous technical support and program enhancements throughout your system lifecycle.
PLC Services & Capabilities
PLC Program Development
Custom programming for Rockwell Automation and Siemens platforms, including ladder logic, structured text, and function blocks for production-critical applications.
System Optimization & Troubleshooting
Analyzing existing PLC programs to identify inefficiencies, bottlenecks, and reliability issues. Implementing optimizations to improve performance and reduce downtime.
Legacy System Modernization
Upgrading older PLC platforms (older CompactLogix, S7-300, etc.) to current architectures while preserving your process logic and operational requirements.
Multi-Platform Integration
Designing systems that seamlessly integrate Rockwell and Siemens controllers with third-party devices, ensuring reliable communication across your plant floor.
Motion Control & Advanced Functionality
Implementing motion control systems, safety programming (SIL/PLd), and advanced PLC features for precision manufacturing and complex processes.
Redundancy & High-Availability Systems
Designing fault-tolerant PLC architectures with redundancy strategies to minimize unplanned downtime in critical production environments.
Data Extraction & Real-Time Reporting
Configuring PLCs to efficiently collect and export production data to MES, SCADA, and analytics platforms for visibility and decision-making.
Program Documentation & Knowledge Transfer
Creating comprehensive documentation and providing training to your maintenance and engineering teams, ensuring long-term sustainability of your systems.
Why Modernize Your PLC Systems?
Modern PLC platforms offer significant advantages over legacy systems:
- Improved Reliability: Newer architectures with better diagnostics and redundancy capabilities
- Enhanced Connectivity: Native support for Ethernet, OPC UA, and cloud integration
- Operational Visibility: Real-time access to machine and process data for analytics and decision-making
- Reduced Maintenance Burden: Better documentation, standardized programming, and broader ecosystem support
- Future-Ready: Easier to integrate emerging technologies and adapt to evolving production requirements
Our Approach
At DataFlow Controls, we bring practical industrial engineering expertise to every PLC modernization project:
- Platform Expertise: Deep technical knowledge of Rockwell and Siemens ecosystems, best practices, and optimization techniques.
- Production-First Thinking: All solutions prioritize plant reliability, operator safety, and seamless integration with existing workflows.
- Risk Mitigation: Careful planning and testing protocols to ensure smooth transitions and minimize production disruption.
- Knowledge Preservation: We document your systems and transfer knowledge to your teams, ensuring long-term sustainability.
- Custom Solutions: No off-the-shelf templates—every system is engineered around your specific production requirements.
- Ongoing Partnership: Continuous support and optimization as your operations evolve and grow.
Rockwell Automation & Siemens Expertise
Rockwell Automation platforms:
- CompactLogix & ControlLogix systems
- Studio 5000 environment
- Connected Components Workbench
- EtherNet/IP and redundancy design
Siemens platforms:
- SIMATIC S7-1200 & S7-1500 controllers
- TIA Portal engineering software
- PROFINET and PROFIBUS communication
- Industrial edge and cloud connectivity
Whether you're optimizing existing systems, modernizing legacy infrastructure, or building new production-ready applications, our team brings hands-on expertise and manufacturing experience to ensure your PLC systems perform reliably and integrate seamlessly with your broader automation ecosystem.
Ready to modernize your PLCs? Let's talk about your automation challenges.