As manufacturing facilities expand, automation systems often evolve over many years. New production lines are added, conveyor systems are extended and different generations of PLC hardware are introduced. While this supports growth, it can also leave manufacturers relying on ageing control systems that become increasingly difficult to maintain.
That was the challenge facing Servier Laboratories in Arklow.
The pharmaceutical facility operates a conveyor system that transfers palletised products from two production areas to a shared warehouse. The original installation was completed in 2002, with a second conveyor line added in 2008. Each operated on its own PLC, creating two separate control systems for one continuous production process. As both platforms reached end-of-life, Servier required a modern solution that would improve reliability, simplify maintenance and provide a single control platform across the entire conveyor network.
The Challenge
Replacing two legacy PLCs was only part of the project.
The conveyor system included elevators, rotating transfer sections and shared conveyor zones where both production lines merged. Maintaining production while replacing the control system required careful planning, particularly where both lines depended on the same conveyor infrastructure.
Servier also wanted to improve operational visibility, modernise safety functions and introduce structured alarm management and reporting without disrupting production.
The Solution
BONNER designed and implemented a new B&R APROL automation platform to replace both legacy PLC systems with one integrated control environment.
The new system provides a consistent HMI across the facility, allowing operators and maintenance teams to monitor the complete conveyor network through a single visualisation platform. A resilient PowerLink ring network improves communications, while B&R X20 Safety modules provide modern functional safety with automatic, manual and maintenance operating modes.
Structured alarm management, secure TosiBox remote access and APROL reporting were also incorporated, giving operators greater visibility while simplifying maintenance and troubleshooting.
The project was developed in close collaboration with Servier’s engineering team and aligned with the site’s existing operating procedures and equipment standards.
Every element of the control strategy, from conveyor sequencing and line priorities to safety functions and recovery following power interruptions, was carefully designed to ensure a smooth transition from the legacy control systems.
The Outcome
Replacing two ageing PLC systems with one integrated automation platform has significantly improved maintainability, operational visibility and long-term reliability.
Operators now work from a single control interface, maintenance teams benefit from improved diagnostics and structured alarm handling, and the resilient network architecture helps maintain production should communication faults occur.
The new platform also provides modern reporting, secure remote engineering access and a scalable foundation for future expansion, ensuring the conveyor system can continue supporting pharmaceutical production for years to come.
BONNER helps manufacturers modernise conveyor systems, migrate legacy PLCs and implement integrated automation platforms that improve reliability, simplify maintenance and provide greater operational visibility.
Whether upgrading an ageing control system or planning a wider automation project, we deliver solutions designed to support production today while preparing facilities for tomorrow.