Upgrade: Controls & HMI | Industry: Mining
Real Results on the Plant Floor
At a Midwestern aggregate processing facility, this quarry control system upgrade delivered measurable improvements across reliability, maintenance, and operator performance.
- Reduced controls-related downtime by eliminating obsolete PLCs, aging I/O hardware, and legacy communication networks
- Improved troubleshooting speed, driven by enhanced HMI visibility and standardized, asset-based tagging
- Eliminated reliance on unsupported control platforms, significantly reducing risk tied to spare parts availability and system failures
- Improved operator response time, enabling faster identification and resolution of system issues
The result is a system that no longer operates reactively — but runs predictably, efficiently, and with significantly less operational risk.
The Base Problem: Where Risk Creeps In
The quarry system is a critical production backbone, supporting continuous material flow through crushing and processing operations. Mechanically, the system was sound and had proven reliable over years of operation.
But the controls told a different story.
The system relied on legacy SLC PLC platforms, aging I/O hardware, and outdated HMI applications. Communication was built on older network infrastructure that no longer aligned with modern plant standards. Over time, this created a growing gap between what the equipment could do mechanically and what the control system could support.
The issue wasn’t a single failure — it was a gradual loss of reliability.
Maintenance teams were spending more time tracking intermittent faults. Replacement parts were becoming harder to source, often requiring refurbished components or extended lead times. When problems occurred, operators had limited visibility into system conditions, slowing response and increasing downtime.
At the same time, integrating newer equipment or expanding the system became increasingly difficult due to outdated communication architecture. What emerged was a familiar but critical risk: a mechanically reliable system being constrained by an increasingly fragile and unsupported control system.
Why Controls Fail Before Mechanics
In systems like this, mechanical components are built for longevity. Crushers, conveyors, and structural elements can operate reliably for decades with proper maintenance.
Control systems cannot.
PLC platforms, HMIs, and I/O systems have shorter lifecycles. As they age, they become obsolete, unsupported, and harder to troubleshoot. Failures become less predictable, and maintenance becomes more reactive.
Over time, the system’s weakest point shifts — from mechanical reliability to control system limitations. Modernizing the controls restores stability, improves diagnostics, and re-establishes long-term supportability.
The Challenge: Upgrade Without Stopping Production
Upgrading the quarry system was not simply a technical challenge — it was an operational one.
This system could not be taken offline for extended periods. Production had to continue, even as the controls were being replaced.
That meant the solution needed to be implemented in a way that minimized disruption while still delivering meaningful improvements.
Axis Engineering addressed this by structuring the project in phases, allowing critical upgrades to occur incrementally. This approach reduced risk, maintained production continuity, and ensured the system could transition to modern architecture without major shutdown events.
Modern Upgrade Architecture
Rather than patching individual components, the solution was designed as a complete controls modernization.
Legacy PLC systems were migrated to a ControlLogix platform, creating a centralized and scalable control architecture. Existing RSLogix 500 programs were converted into Studio 5000, allowing the system to operate on a modern, supported software platform.
Communication was transitioned from legacy networks to Ethernet-based infrastructure, improving reliability and enabling integration with newer systems.
At the hardware level, aging SLC I/O systems were replaced with ControlLogix remote I/O, supported by new control panels designed for long-term maintainability.
The HMI layer was modernized as well, with migration to FactoryTalk View SE and consistent retagging across systems.
This was not just an upgrade — it was a reset of the control system foundation, aligning the plant with current standards and future needs.
Phase 2 Focus: Hardware and Visibility
While Phase 1 established the foundation, Phase 2 delivered the most visible and operationally impactful improvements.
The focus shifted to replacing legacy I/O infrastructure across the crusher and conveyor systems. This required not just new hardware, but a complete reorganization of how the system was structured and identified.
New ControlLogix I/O racks were installed, and PLC programs were updated with asset-based tagging. This change improved clarity across the system, making it easier for maintenance teams to identify, isolate, and resolve issues.
At the same time, the HMI system was enhanced to reflect these improvements. Screens for the Primary Crusher and Burner Floor were updated with improved graphics and usability. These updates were tested prior to installation and reviewed with the customer to ensure they aligned with operator expectations and workflows.
The result was not just a visual upgrade — but a functional improvement in how operators interact with and understand the system.
Before vs. After: Quarry System Controls
This transformation highlights a common pattern in legacy systems: the mechanical equipment continues to perform, but outdated controls create increasing operational risk. By modernizing the control architecture, this quarry was able to restore reliability, improve visibility, and position the system for long-term success.
| Area | Before Upgrade | After Upgrade |
|---|---|---|
| Control Platform | Legacy SLC PLCs nearing end-of-life | Modern ControlLogix platform with full OEM support |
| Communication Network | Obsolete DH+ and limited connectivity | Ethernet-based architecture enabling faster, scalable communication |
| I/O Infrastructure | Aging SLC I/O racks prone to faults and difficult maintenance | New ControlLogix remote I/O with improved reliability and organization |
| HMI System | Outdated interfaces with limited diagnostics and visibility | FactoryTalk View SE with improved graphics, alarms, and operator insight |
| Troubleshooting | Time-consuming fault isolation with limited system visibility | Faster troubleshooting with asset-based tagging and improved diagnostics |
| Downtime Risk | High risk due to obsolete hardware and spare part limitations | Reduced controls-related downtime risk through modern, supported hardware |
| Maintenance Effort | Reactive maintenance, frequent time spent chasing intermittent issues | More proactive maintenance with clearer system structure and diagnostics |
| System Integration | Difficult to integrate with newer equipment or expand system | Scalable architecture ready for future upgrades and integration |
| Operator Efficiency | Slower response due to limited system feedback | Faster response with improved visibility and intuitive screens |
Our Turnkey Upgrade Approach
This project was executed as a full turnkey modernization, covering engineering, implementation, and startup. Axis Engineering provided:
- Electrical design and control panel fabrication
- PLC program conversion and integration
- HMI redevelopment and retagging
- Offline testing using emulation
- On-site startup, I/O checkout, and production support
By validating the system before installation, risks were identified early and commissioning was significantly smoother. This approach ensured that the transition from legacy to modern controls was controlled, predictable, and efficient.
Real Impact: Beyond the Upgrade
The benefits of this project extended beyond replacing obsolete hardware.
Operators now have the visibility needed to respond quickly and confidently to system conditions. Maintenance teams spend less time diagnosing issues and more time maintaining performance.
The system is now structured, standardized, and easier to expand — providing a foundation for future upgrades and integration.
Most importantly, the plant is no longer dependent on aging, unsupported control components. Instead of reacting to failures, the operation now runs on a system designed for stability, clarity, and long-term reliability.
Manufacturing Peace of Mind℠
For this aggregate processing facility, this upgrade represents more than a technical improvement. It delivers confidence:
- Confidence in system reliability
- Confidence in operator visibility
- Confidence in long-term supportability
That is what Manufacturing Peace of Mind℠ looks like in a quarry operation.
Looking to Modernize Legacy Systems?
Many facilities are operating equipment that is mechanically sound but limited by outdated controls. A modern controls upgrade can:
- Reduce downtime risk
- Improve troubleshooting and visibility
- Extend the life of critical assets
- Create a scalable foundation for future growth
Axis Engineering delivers turnkey control system modernization designed to help manufacturers run smarter, safer, and more reliably.
Learn more about our work with surface mining and aggregate operations on our Surface Mining Controls page — including a free risk assessment built specifically for mining operations.
Contact Axis Engineering to discuss modernizing your control system.