The challenge
What needed to change.
Ageing equipment limited performance, supportability and the ability to make further improvements to the production process.
Machine builds · Industrial manufacturing
Plastic dip-moulding retrofit
A multidisciplinary retrofit that modernised ageing machinery and improved performance, control and energy use.
ClientSpecialist manufacturerSectorIndustrial manufacturingPrimary disciplineMachine builds
Adbro’s approach
How the solution was engineered.
Mechanical changes, electrical panels, drives, controls and a new operator interface were developed as one coordinated retrofit.
The outcome
What the project delivered.
The retrofit delivers higher performance, improved energy efficiency and a modern platform that is easier to operate and support.
Technical delivery
Inside the engineered solution.
The detail below shows how the main equipment, software and interfaces were brought together—not just what the project achieved.
System scope
- Existing-machine condition and interface survey
- Mechanical refurbishment and modification
- Replacement control panel and field wiring
- Modern motor drives and motion control
- PLC sequencing and interlocks
- New HMI for operation and diagnostics
- Commissioning around retained process equipment
Retain, replace or modify
The retrofit scope separated productive mechanical assets from components that limited performance or supportability, concentrating investment where it changed the operation.
Drive and sequence modernisation
Updated drives, sensors and PLC control provide more consistent movement and a clearer sequence structure while retaining the core dip-moulding process.
Operator and maintenance visibility
The HMI presents operating modes, setpoints, interlocks, alarms and diagnostic states in one place, reducing reliance on knowledge held only by individual operators.
Coordinated multidisciplinary cutover
Mechanical work, panel replacement, field installation and software commissioning were planned as one retrofit so retained equipment and new controls could be proven together.
Verification & handover
Factory and site testing covered manual movement, automatic sequencing, drive behaviour, interlocks, alarm handling, stop and restart conditions, and sustained production proving with the retained process equipment.
Project highlights
Machine retrofitDrives & motionHMIEnergy efficiency
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