CONVERGIX develops automation and control solutions for manufacturing operations, addressing legacy system obsolescence, process optimization, and operational continuity requirements. We modernize PLCs, DCS systems, and control networks while implementing asset management and disaster recovery protocols that ensure reliable performance, reduced downtime, and sustained plant safety across your entire control infrastructure.
Industrial Automation & Control Systems
PLC Modernization & Process Integration
PLC Modernization & Process Integration
Challenge
Industrial Control Systems: Legacy Infrastructure & Operational Continuity
As facilities pursue digital transformation and Industry 4.0 technologies, manufacturers must balance modernization needs with operational continuity, asset compatibility, and disaster recovery preparedness without compromising process performance or plant safety.
Solution
Control System Modernization: Migration & Asset Management Solutions
At CONVERGIX, we deliver systems that preserve operational continuity while upgrading infrastructure to meet current performance standards and future goals. Our engineering teams design migration solutions for critical control environments, incorporating comprehensive asset management and disaster recovery protocols to minimize risk and maintain process performance.
Capabilities
Automation & Control Components
Turnkey Solutions
Turnkey System Implementation
By comprehensively assessing your automation architecture and collaboratively defining your future state, we ensure seamless integration, minimize implementation risk, increase operational efficiency, and maintain process safety from planning to commissioning.
Consultative Strategy and Scoping
- Provide accurate project scoping and risk identification
- Map technology roadmaps aligned with business priorities
- Begin system configuration while managing legacy infrastructure transitions
Operational Advantages
- Faster project deployment
- Reduced operational disruption
- Smoother transition from legacy to modern control platforms
Fixed-Cost Turn-Key Projects & Embedded Resources
Our implementation approach offers flexibility based on your operational needs and project scope:
- Turn-Key Delivery – Complete project execution from design through commissioning with fixed pricing and defined timelines
- Embedded Resources – Dedicated engineers integrated into your team for ongoing support and specialized expertise
- Vendor-Neutral Approach – Cross-platform capabilities across multiple PLC, DCS, and control system manufacturers
Optimization
Control System Design & Optimization
Outdated control loops and tuning parameters often hinder plant efficiency, with operators unaware of the impact. Our control system optimization uses platforms like PlantESP to assess performance, pinpoint inefficiencies, and apply effective tuning, improving stability, throughput, and quality.
Each engagement features robust data collection, broad DCS/PLC compatibility, and actionable advice for both immediate and sustained improvements, moving operations closer to optimal performance.
Process Control Optimization Benefits
- PID Loop Tuning – Advanced tuning methodologies for improved process stability and reduced variability
- Multi-Variable Analysis – Comprehensive assessment of interdependent control loops and their collective impact on performance
- Continuous Improvement Framework – Baseline establishment, performance monitoring, and ongoing optimization recommendations.
- Platform-Agnostic Approach – Support for all major control system manufacturers and historian platforms
Automation Modernization
Legacy System Modernization
CONVERGIX helps factories upgrade old control systems before they fail. Our team replaces outdated equipment with modern technology that works better, costs less to run, and keeps plants running safely. With experience in both industrial systems and IT, they deliver proven solutions tailored to each customer's needs while protecting critical data during the transition.
Safe, Strategic System Upgrades
Our modernization projects are designed with operational continuity in mind, including:
- Phased Migration Planning – Structured approaches that minimize downtime and preserve process knowledge
- Asset Management & Version Control – Comprehensive documentation and backup procedures for critical control assets
- Disaster Recovery Integration – Proactive planning for system availability and rapid recovery capabilities
- OT/IT Security Considerations – Safe data management practices that protect both operational technology and information systems
PLC & DCS Modernization: End-of-Life System Upgrades
As control systems approach end-of-life, manufacturers face mounting risks, including unsupported hardware, compatibility issues with modern equipment, and increased vulnerability to failures that can halt production.
Our modernization approach addresses these challenges systematically:
- Current State Assessment – Comprehensive evaluation of existing control infrastructure, identifying obsolete components and compatibility gaps
- Migration Strategy Development – Detailed roadmaps that balance modernization goals with operational continuity and budget constraints
- Controlled Implementation – Phased execution that preserves process knowledge while upgrading to current platforms
Benefits
What Automation & Controls Deliver
Operational Reliability
Reduced downtime through modernized control infrastructure and proactive asset management
Process Performance
Increased efficiency through optimized control loops and integrated system design
Business Continuity
Improved system availability and disaster recovery preparedness through comprehensive planning
See how CONVERGIX can strengthen your production environment.
Robotics
Enhance speed, precision, and flexibility in your operations by integrating advanced robotics purpose-built for complex assembly tasks.
Digital Integration
Unlock real-time visibility and optimized performance with digital systems that connect your assembly operations end-to-end.
Material Joining
Strengthen your assembly operations with engineered welding, fastening, and dispensing systems that deliver repeatable joint integrity, optimized cycle times, and reliable, cost-efficient performance.
