About our legacy system upgrade service
Legacy PLCs, SCADA, HMI and drive systems often go unnoticed until they fail - at which point the cost and disruption of an unplanned outage far outweighs what a managed migration would have cost. We upgrade many systems every year, working with customers to plan migrations in advance, structure costs to fit budget cycles, and carry out the work with minimal interruption to production. We also respond when the worst happens and a critical system has failed beyond repair.
Why Nivalis?
We understand the reluctance to touch a system that's still running - even when it's obsolete. The concerns about production disruption and upfront cost are real, and we don't dismiss them. What we offer is a pragmatic, planned approach - an honest assessment of your risk, a migration strategy that works around your schedule, and costs that can be spread across budget cycles. We've helped many businesses move from ageing legacy systems to modern platforms without the unplanned failure they were trying to avoid.
Our process
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01: Assess
Review existing system, identify risks and define scope
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02: Plan
Migration strategy aligned to your production schedule and budget
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03: Build
New system built and programmed in-house
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04: Test
Full testing against existing system before site deployment
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05: Migrate
Controlled on-site switchover with minimal production interruption
Don't wait for something to fail
Legacy control systems are one of the most commonly overlooked risks in industrial operations. A Siemens S5 or Allen-Bradley SLC 500 that has run without issue for twenty years feels like a solved problem - until it isn't. Spare parts become unavailable, support contracts lapse, and the engineers who originally built the system have long since moved on. When failure eventually comes, it comes without warning and at the worst possible time.
The good news is that a carefully planned migration changes the equation entirely. Working around your production schedule, we develop a migration strategy that moves you from an obsolete system to a modern, supported platform with minimal downtime and costs that can be spread to fit your budget. We carry out the full upgrade in-house - new hardware, new software, fully tested - before a controlled switchover on site.
If you have legacy PLC, SCADA, HMI or drive systems that haven't been reviewed recently, talk to us. We'll give you an honest assessment of your risk and a clear view of what a migration would involve - no obligation, no pressure.