Many machines used in industry today are quite often decades old. Although still functioning mechanically, age will undoubtedly be taking its toll on the electrical controls. As the machine becomes more and more prone to malfunctions and breakdowns, downtime costs can rise and replacement parts can be harder to come by.

Modifying part or all of a machine can prove cost effective in the long term. Not only does this help reduce downtime but also ensures you have items of equipment that are still available. This is also the same for software upgrades, which make it easier to back up entire PLC programs and keep them stored.

The use of cheaper alternatives e.g. using AC motors and controls instead of DC can help reduce maintenance costs and also help to make it quicker to get replacements with off the shelf motors.

The added advantage of upgrading machinery is the improvement in safety circuits, making machines and equipment safer to use.