Keep controls modern

To ensure your production remains safe, available, and future-proof

Many production facilities have been running reliably for years. However, the control technology behind them is aging.

SPS systems, operator interfaces, visualizations, servers, networks, and interfaces are often still in use, even though spare parts are becoming difficult to obtain, software versions are outdated, or documentation is no longer complete.

The risk is increasing gradually.

A failure is rarely planned. And when it happens, it doesn't just affect one control system, but often the entire production.

OPDENHOFF helps process industry companies keep their controls modern. Not through blind replacement, but through clear analysis, a solid strategy, and step-by-step modernization during ongoing operations.

So your plant keeps producing. Today, tomorrow, and in the future.

Why Modern Controls Are Crucial

A control system is more than just a control cabinet or a PLC program.

It connects machines, sensors, actuators, scales, dispensers, mixers, silos, operators, recipes, orders, and production data.

If this level becomes obsolete, risks will arise:

Spare parts are becoming scarce

Many older PLC systems, panels, or modules are only available used or not at all anymore.

Knowledge is lost

Programs have been expanded over the years. Often, only specific individuals know why certain functions were implemented in a particular way.

Interfaces are missing

Modern requirements such as ERP integration, digital twins, energy consumption recording, OEE, batch tracking, or AI analysis require clean data and open interfaces.

Security is becoming more challenging

Outdated systems often can no longer be properly secured. This applies to IT/OT security, remote maintenance, user rights, and future requirements such as NIS2.

Downtime is becoming more expensive

The older the control system, the greater the risk that a small defect will lead to a major production failure.

Modernize control systems without rebuilding the plant

Not every system needs to be completely replaced.

Often, it is sufficient to specifically analyze existing technology, assess risks, and modernize control step by step.

OPDENHOFF considers not only the PLC, but the entire process:

Assessment

We are inspecting controls, control cabinets, HMI systems, networks, programs, interfaces, documentation, and spare parts situation.

Risk analysis

We assess which components are critical, where a failure would be particularly costly, and which systems should be modernized first.

Retrofit Concept

We are developing a clear modernization plan, from migrating individual assemblies to the complete renewal of PLCs, HMIs, SCADA, or process control systems.

Implementation During Normal Operations

We are planning renovations to reduce downtime and minimize production interruptions.

Future-Proof Database

We lay the groundwork for digital twins, OPDPRO.CARE, AI analytics, OEE, maintenance, quality, and energy optimization.

From S5 to S7, from WinCC to OPDPRO.CARE

OPDENHOFF knows classic and modern automation systems from practical experience.

We assist companies with the migration and modernization of control systems, visualization systems, and process control systems.

Typical tasks include:

PLC Migration

For example, from older control systems to modern systems such as the Siemens S7-1500 or comparable platforms.

HMI and SCADA Modernization

Modernization of user interfaces, panels, WinCC systems, and process visualizations.

Control Cabinet and Hardware Modernization

Inspection and replacement of assemblies, power supplies, communication systems, safety equipment, and field connections.

Interfaces and Data Connectivity

Integration with ERP, MES, OPDPRO.CARE, scales, dispensers, sensors, energy meters, and digital twins.

Documentation and Structure

Preparation of programs, plans, system architecture, functions, and interfaces.

Modern controls are the basis for the digital twin

A modern control system does more than just provide signals.

It provides context.

Which plant is running?
Which order is active?
Which recipe is being used?
What raw materials are used?
Which fault occurs?
What energy is being consumed?
What quality was achieved?

Exactly this information is the basis for a digital twin.

With OPDPRO.CARE Let's connect control technology, production data, plant structure, orders, raw materials, maintenance, quality, and energy into a continuous picture of the value stream.

This is how modern control systems become more than just automation.

It forms the basis for transparency, better decisions, and AI-powered process optimization.

Your advantages

Lower risk of failure

Critical old components are identified and specifically replaced.

Higher plant availability

Modernized controls increase the stability and maintainability of your production.

Better usability

Modern HMI and SCADA systems make plant operation more understandable and safer.

Open interfaces

Your system will be connectable for ERP, MES, OPDPRO.CARE, digital twins, and AI.

No reliance on individual knowledge

Programs, structures, and documentation are processed in an understandable way.

Investment security

You are modernizing step-by-step, instead of having to act unplanned under pressure.

Which systems is this relevant for?

This landing page is aimed at companies in the process industry that want to continue operating, modernize, or make existing plants digitally compatible.

This is particularly relevant for:

Raw material handling

Silos, Big Bag stations, pneumatic conveying, scales, feeders, and material flows.

Mixing and kneading processes

Mixers, kneaders, compounding, recipe control, and batch logs.

Extrusion and further processing

Extruder, Calender, Winder, Cooling sections, Cutting systems, and Packaging.

Production lines with older PLC technology

Systems with obsolete controls, old panels, outdated PCs, or unclear documentation.

Facilities with growing digitalization needs

Productions that in the future ERP integration, digital twins, OEE, energy analysis, or AI.

Our Approach

1. Control check

We analyze your existing control technology and identify technical, organizational, and economic risks.

Modernization Plan

You will receive a clear recommendation on which measures are necessary, sensible, or to be planned in the long term.

3. Implementation

We are modernizing PLCs, HMIs, SCADA, interfaces, Control cabinets and documentation according to a coordinated concept.

4. Establish data capability

We are creating the technical foundation for OPDPRO.CARE, digital twins, and modern analyses.

5. Accompany operation

We also support you after the modernization with service, training, support, and further development.

Don't wait for the control to fail

Many modernizations only begin when a component is defective, an old PC no longer starts, or no one can safely modify the program anymore.

Then a planned investment becomes an emergency.

It's better to check early on which controls are critical and how the system can be kept up-to-date step by step.

This way you maintain control over time, costs, and implementation.

OPDENHOFF as a partner for modern control technology

For over 55 years, OPDENHOFF has been supporting industrial production processes.

We know systems not only from the control cabinet, but from the entire value stream. From raw material handling through dosing, mixing, kneading, and extrusion to packaging and data evaluation.

We combine this experience with modern automation, digital twins, and AI-powered process solutions.

Our goal is not to innovate technology for technology's sake.

Our goal is to make your production safer, more transparent, and more future-proof.

Open. Pragmatic. Manufacturer-independent. With a view of the entire process.