Which industries gain most from PLC replacement?

High-volume machine industries like packaging, textile, and CNC manufacturing usually see the strongest hardware cost advantage from PLC replacement with custom industrial control boards.

Can process equipment use board-level control reliably?

Yes, with proper I/O isolation and communication design, board-level control can meet industrial runtime requirements for process equipment.

Is board-level control suitable for smart factory upgrades?

Yes. Protocol-ready architecture supports distributed control, production data integration, and connectivity with MES/SCADA systems.

Industry Guide

PLC Replacement by Industry Scenario

Different industries require different migration priorities when moving from traditional PLC modules to board-level control. Use this page as a planning baseline for evaluating PLC replacement ROI across your target markets.

For equipment manufacturers producing 50+ machines per year, board-level control can reduce hardware BOM by 30–60% compared to branded PLC configurations. The key is identifying applications where PLC module standardization is not critical and custom I/O mapping delivers clear technical and cost advantages.

Packaging Machinery

Packaging machines typically require precise motion control, high I/O count, and stable cycle-time performance. Custom boards excel here because batch volumes are high enough to amortize engineering cost, and the I/O configuration can be optimized for each specific machine generation.

Textile & Process Equipment

Textile machinery and process equipment prioritize communication reliability, long continuous runtime, and practical maintenance in factory environments. Board solutions provide isolated I/O, multi-protocol support (RS485, CAN, Ethernet) and compact form factors suited for harsh industrial conditions.

Smart Manufacturing Lines

Smart factory applications benefit from protocol-ready architecture that supports distributed control nodes, real-time data acquisition, and integration with MES/SCADA systems. Custom boards provide flexibility to combine field-level protocols with IT connectivity in a single platform.

CNC & Machine Tools

CNC machines require deterministic real-time control for multi-axis coordination. EtherCAT-based boards deliver sub-millisecond synchronization without the overhead of full PLC module stacks, reducing both cost and cabinet space.

Environmental Monitoring

Environmental and water treatment systems need reliable data acquisition with low power consumption and long-term stability. STM32F4/F1 boards provide cost-effective solutions with RS485/Modbus connectivity for sensor networks.

Vending & Service Equipment

High-volume commercial equipment like vending machines benefit from extremely cost-optimized boards with Ethernet connectivity for remote monitoring and firmware updates.

FAQ

Industry Migration Questions

Which industry is best for first migration?

OEMs with stable machine architecture and clear annual volume are the best first candidates. We recommend starting with machines that have well-defined I/O requirements and proven production processes.

Does migration interrupt production line delivery?

Typical approach is pilot validation first, then phased replacement for controlled delivery risk. Most customers run both PLC and board versions in parallel during the transition period.

Can old protocols be retained during migration?

Yes, legacy communication protocols can be retained while upgrading core controller hardware. Our boards support RS485, CAN, and Ethernet simultaneously for backward compatibility.

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