We provide controls retrofits, PLC migrations, and process upgrades for plastics processing equipment — injection molding machines, extruders, and blow molding machines — replacing obsolete or damaged control systems with modern platforms while reusing existing mechanical and hydraulic components to minimize cost and downtime.
Full PLC migration on extrusion lines — including reverse-engineering existing control logic, rewiring all I/O to the new platform, and reprogramming HMIs to preserve existing operator workflows. We deliver simultaneous process upgrades alongside the migration, such as new calibrator control systems and independent closed-loop temperature zones, all within compressed shutdown windows.
Development of custom control algorithms for precision process control on plastics equipment, including multi-zone independent PID temperature control across oven sections and dynamic pressure compensation that adjusts for line speed variations to maintain consistent product quality.
Complete controls replacement for injection molding machines, including new PLC, HMI, and drive packages designed to work with a range of existing hydraulic valve configurations. By reusing existing valves and mechanical components, we significantly reduce retrofit cost. We’ve done similar conversions for blow molding machines using the same approach.
How CSI replaced the legacy control system on a plastics extrusion line with a modern Siemens PLC platform — while simultaneously adding a new calibrator control system and upgrading oven temperature control to ten independent zones.
