Delivering Seamless SLC Migrations

SGA has been a trusted partner of the leading bakery, Tip-Top, in Victoria, Australia, providing continuous 24/7 site support since 2022.

As part of our ongoing commitment to enhance their plant production and reliability, SGA has performed several modernisation projects for critical plant areas, migrating from legacy to current/supported hardware, drastically improving the site’s resilience to cyber threats.

In 2023, we executed three planned migration projects: a Mixer, Cratewash Conveyor, and Cooler upgrade.

Key Client Benefits
  • Ignition SCADA project tailored to the plant
  • Allen Bradley ControlLogix PLCs as main controllers
  • Integration of auxiliary PLCs, valves, drives, and transducers
  • Operator access via control room, onsite tablets, and remote login
  • Historical data, audit logs, and automated reporting for supervisors
The result is a fully automated, round-the-clock plant with clear visibility, simplified supervision, and reliable traceability.
project overview

How did we do it?

SGA’s strategic approach to the control system upgrades led to seamless and easily repeatable migrations.
The innovative migration techniques employed halved the traditional implementation time. This allowed the bakery to experience minimal downtime with no disruption to production.

For each migration, SGA carefully upgraded the bakery’s systems to the latest CompactLogix platform, focusing on minimising disruptions and extending the life of the manufacturing assets.

  • Used the Integrated Architecture® Builder tool by Rockwell Automation to map out a seamless migration process.
  • Managed the procurement of CompactLogix 5380 PLC hardware and the SLC to CompactLogix converter kit.
  • Coordinated the integration of new I/O wiring systems, ensuring compatibility with existing plant infrastructure.
  • Performed automated PLC code conversions and reviews from RSLogix500 to Studio5000.
  • Used advanced conversion tools to minimise development time and streamline the upgrade.
  • Conducted rigorous testing prior to commissioning to ensure all systems met operational standards.
  • Implemented thorough cutover procedures to reduce downtime and ensure system reliability.
  • Maintained regular fortnightly meetings to keep the client informed and involved in decision-making.
  • Provided 24/7 support during critical phases to address any challenges promptly.