Client with Three Legacy Controlled Casting Pits
Methodical Casting Pit Systems Upgrade
Industry Metals
Product/Material Handled Casting pit materials
System Deliverables
Legacy System Reverse Engineering
Working from aging GE 9030 PLCs and HMIs, the team reconstructed control narratives and drawings-building a clear modernization roadmap for all three casting pits.
Advanced CompactLogix Implementation
Rockwell CompactLogix controllers and PanelView Plus HMIs brought predictive speed algorithms and tighter PID control to every area of the operation.
Segmented Ethernet Network
Each casting pit got its own Stratix switches and segmented networks, keeping communication clean and reliable between PLCs, HMIs, and remote I/O.
Results in Action

Enhanced Process Control
Predictive and PID-based algorithms took a lot of guesswork out of casting, keeping operations consistent and product quality steady.
Efficient Installation and Changeover
Comprehensive documentation and on-site supervision made installation fast, and the system switchover nearly seamless-with minimal downtime.


Future Scalability
The updated platform sets the stage for ongoing modernization and a potential plant-wide Ignition rollout for better visibility across the board.
