HMI and Operator Interface Upgrades
Older touchscreens and operator panels can be difficult to navigate, repair or replace. A modern HMI can provide clearer controls, better diagnostics and faster access to machine information.
HMI modernization may include:
- Replacement of obsolete operator panels
- New touchscreen interfaces
- Improved machine-status displays
- Clearer alarm messages
- Fault-history tracking
- Recipe and setup management
- Maintenance reminders
- Production counters and performance data
- Password and access-level controls
- Simplified operator navigation
Improved operator interfaces can reduce troubleshooting time and help operators respond more quickly when machine conditions change.
Drive and Motor Control Upgrades
Obsolete or unreliable drives can affect speed control, synchronization, registration and overall production consistency. manroland Goss can evaluate existing AC, DC, servo and motor-control systems and recommend practical upgrade options.
Drive-system services may include:
- AC and DC drive replacement
- Servo-drive upgrades
- Motor-control modernization
- Drive tuning and commissioning
- Speed and torque control improvements
- Sectional drive upgrades
- Communication-network integration
- Replacement of unsupported drive hardware
- Improved drive diagnostics
- Motor and feedback-device evaluation
These upgrades may be completed as standalone projects or incorporated into a larger machine-controls modernization.
Control Panel Modernization
Older control cabinets may contain discontinued components, undocumented modifications or systems that are difficult to troubleshoot safely. A control-panel upgrade can improve organization, supportability and long-term maintenance.
Control-panel modernization may include:
- New electrical control panels
- Replacement of obsolete components
- Updated power distribution
- Improved cabinet cooling
- New terminals and wiring
- Modern circuit protection
- Network and communication hardware
- Safety relays and control components
- Updated labels and documentation
- Panel testing and commissioning
Our engineering team can also evaluate which components should be retained and which should be replaced to control project scope and cost.
Corrugated Equipment Automation Improvements
Controls modernization can do more than replace outdated components. It can also improve how the equipment operates.
Potential automation improvements include:
- More reliable machine sequencing
- Improved setup and changeover processes
- Automatic positioning
- Recipe-based machine settings
- Improved synchronization between sections
- Enhanced fault detection
- Reduced manual adjustments
- Production-data collection
- Remote diagnostic access
- Integration with plant systems
Automation projects are developed around the specific production challenges and opportunities identified during the equipment evaluation.
Controls Support for Flexo Folder Gluers
Flexo folder gluers rely on coordinated control of feeding, printing, slotting, die cutting, folding and gluing sections. Problems in one section can affect production throughout the machine.
Our flexo folder gluer controls support may include:
- PLC and HMI replacement
- Feeder-control troubleshooting
- Print-section drive support
- Registration-system improvements
- Slotter and die-cutting controls
- Folding-section synchronization
- Glue-system controls
- Safety-system upgrades
- Alarm and diagnostic improvements
- Communication-network modernization
Learn more about our flexo folder gluer service and upgrades.
Controls Support for Other Corrugated Equipment
manroland Goss can evaluate controls and electrical systems across a range of corrugated converting and packaging equipment, including:
- Rotary die cutters
- Folder gluers
- Flexo printing and converting equipment
- Stitchers
- Stackers
- Bundlers
- Palletizers
- Laminators
- Feeders
- Conveyors
- Material-handling systems
- Finishing equipment
Available support depends on the equipment, controls platform, documentation and required scope.
Safety-System Modernization
Older safety systems may no longer meet current operational needs or may rely on difficult-to-source components. Controls projects can include an evaluation of machine safety functions and related electrical systems.
Safety improvements may include:
- Safety PLC upgrades
- Safety-relay replacement
- Emergency-stop circuit modernization
- Guard-switch integration
- Light-curtain integration
- Safety-zone improvements
- Updated diagnostics
- Safety-circuit documentation
- System validation and testing
Safety requirements and project recommendations are evaluated based on the machine, application and applicable facility standards.
Remote Diagnostics and Support
Modern control systems can make it easier to diagnose equipment faults and support plant personnel. Where appropriate, manroland Goss can incorporate secure remote-support capabilities into a controls upgrade.
Remote-support features may include:
- Secure VPN access
- Remote PLC diagnostics
- HMI troubleshooting
- Drive fault analysis
- Program backup and recovery
- Software support
- Remote engineering assistance
- Faster identification of recurring issues
Remote access does not replace all on-site service, but it can shorten diagnostic time and help determine what support, parts or expertise may be required.
Electrical Documentation and Software Backups
Incomplete drawings and missing software backups can make future maintenance more difficult. Controls modernization projects can include updated documentation to support plant personnel and future service work.
Documentation may include:
- Updated electrical schematics
- Control-panel layouts
- Input and output lists
- Network drawings
- Component lists
- PLC and HMI software backups
- Drive parameter backups
- Operating descriptions
- Troubleshooting information
- Recommended spare-parts lists
Signs Your Corrugated Machine Controls May Need an Upgrade
It may be time to evaluate a controls upgrade when you experience:
- Frequent PLC or drive faults
- Intermittent electrical problems
- Unsupported or discontinued controls
- Difficulty finding replacement components
- Failed or unreliable operator touchscreens
- Incomplete electrical drawings
- Lost PLC or HMI programs
- Slow troubleshooting
- Poor machine diagnostics
- Recurring communication errors
- Inconsistent machine sequencing
- Excessive manual setup
- Limited remote-support capabilities
- Increasing downtime caused by electrical systems
Addressing obsolescence before a critical failure can provide more time to plan the project and reduce emergency downtime.
Our Controls Upgrade Process
1. Equipment Evaluation
We review the machine, controls platform, electrical condition, documentation and production requirements.
2. Scope Development
Our team identifies obsolete components, reliability concerns and opportunities for improvement.
3. Engineered Solution
We develop a customized upgrade plan covering hardware, software, electrical engineering and installation requirements.
4. Installation and Testing
The new controls are installed, programmed and tested based on the agreed project scope.
5. Commissioning and Support
Our team supports startup, verifies machine operation and provides available documentation and training.
Why Choose manroland Goss?
manroland Goss brings decades of experience supporting complex production machinery, industrial controls, drive systems and engineered upgrades.
Corrugated manufacturers rely on our team for:
- Experienced electrical and controls engineers
- Customized solutions rather than generic retrofit packages
- Mechanical and electrical capabilities from one source
- Support for equipment from multiple manufacturers
- PLC, HMI, drive and safety-system expertise
- On-site and remote support
- Obsolescence planning
- Updated drawings and software documentation
- Solutions focused on long-term reliability and supportability
Frequently Asked Questions
Can you replace an obsolete PLC on corrugated equipment?
Yes. Our controls specialists can evaluate the current PLC, input and output systems, machine program and connected equipment to recommend a migration or replacement solution.
Do you work with equipment not manufactured by manroland Goss?
Yes. We support corrugated and packaging equipment from multiple manufacturers. Contact us with the manufacturer, model and controls platform so we can evaluate the application.
Can you upgrade only the HMI without replacing the PLC?
In some cases, yes. Compatibility, software availability and the condition of the existing control system must be evaluated before recommending an HMI-only upgrade.
Can you replace obsolete drives?
Yes. We can evaluate AC, DC, servo and motor-control systems and recommend replacements based on the machine and application.
Will we receive updated electrical drawings?
Updated documentation can be included in the project scope. The available documentation depends on the existing equipment and the extent of the upgrade.
Can controls upgrades be completed during a planned shutdown?
Yes. Many projects can be scheduled around planned shutdowns. Larger upgrades may require advance engineering, panel construction, software development and testing.
Can remote access be added?
Secure remote-support capabilities may be incorporated where appropriate and approved by the customer’s information technology and security requirements.
Do you provide operator or maintenance training?
Training can be included based on the project scope and the systems being installed.
Request a Corrugated Controls Evaluation
Whether you are dealing with an obsolete PLC, unreliable drives, an aging HMI or a complete controls system that is becoming difficult to support, manroland Goss can help evaluate the next step.
Provide the equipment manufacturer, model, controls platform, current problems and production requirements when contacting us.
Contact Our Corrugated Controls Team
