Malone Group completed a 12-month controls upgrade for a cosmetics manufacturer in the UK, replacing seven obsolete PLCs with six new Omron Sysmac PLCs. One PLC was removed from the network by improving data communication, and the PLC software was fully standardised across all systems to support ongoing maintenance. All work was carried out during weekend-only shutdowns, with the plant handed back to production every Monday morning, resulting in no production losses. The network was upgraded to allow continuous data logging to an SQL database for production reporting, and remote access was configured to enable ongoing support and off-site commissioning when required. Malone Group planned and delivered system upgrades within strict production constraints, completed work on time, and maintained plant operation throughout.
