Case Study: an aluminum manufacturer boosts reliability and cuts downtime with Polaris Automation's controls upgrade

Aluminum Manufacturer cuts downtime with Polaris Automation after a six-month controls upgrade

A major aluminum manufacturer faced frequent production downtime due to its outdated control equipment and obsolete software that had been in place for over 20 years. They enlisted Polaris Automation to execute a comprehensive full system upgrade to resolve these challenges.

Polaris Automation consolidated six legacy PLCs into a single Rockwell controller while preserving existing I/O systems. They used ProSoft modules to run both systems in parallel for validation before a successful cutover. The project was completed ahead of schedule, resulting in a production line that now operates with significantly increased reliability and very little downtime.

Aluminum Manufacturer