Powering a Seamless, Multi‑Level Modernization
When a major rubber compounding facility set out to modernize a critical three‑level mixing operation, they needed an installation partner capable of executing high‑risk, high‑precision industrial work across a complex footprint. ASBECO delivered.
The Challenge
The site’s aging PLC‑5 architecture spanned three physical areas – the ground‑floor drive room, mezzanine seal oil system, and second‑story mixer and scale control zone. Much of the equipment was decades old, embedded in tight mechanical spaces, and operating under strict NEMA 12 and Class 2/Div 2 requirements. The project demanded:
- Safe removal of legacy hardware
- Installation of multiple new custom enclosures
- Migration of I/O from 120VAC to 24VDC
- Clean, disciplined cable management across multiple elevations
- Coordination with both plant operations and parallel integration work
This was not a standard swap‑and‑drop job. It required a field‑team with discipline, experience, and the ability to deliver with zero downtime surprises.
ASBECO’s Execution
ASBECO led all physical execution for the modernization, managing the demolition, installation, and onsite commissioning of the new system infrastructure.
Key accomplishments included:
- Safe Removal of Legacy PLC‑5 Infrastructure
ASBECO dismantled decades-old control hardware—1771 I/O racks, outdated seal oil system controls, obsolete VFD assemblies, and scale system enclosures—while protecting surrounding production assets and maintaining strict housekeeping standards.
- Installation of Custom-Built Industrial Enclosures
Across all three floors, ASBECO installed new NEMA 12 / Class 2 Div 2 rated panels purpose‑built for the upgraded controls platform. Their team ensured all mounting, spacing, ventilation, and conduit layout met code and client standards.
- Full I/O Voltage Migration
The client used this modernization to convert the majority of system I/O from 120VAC to 24VDC.
ASBECO executed the transition flawlessly, coordinating wire replacement, device conversions, terminations, and field testing to ensure every new circuit came online cleanly.
- Multi‑Level Coordination & Precision Execution
ASBECO’s field technicians worked across the drive room, mezzanine, and upper‑level mixer areas—navigating large equipment, tight mechanical spaces, and active plant conditions. Their structured planning and communication assured:
- Zero conflicts with plant operations
- Zero rework for integration partners
- Zero safety incidents
- Supporting a Smooth Startup
During commissioning, ASBECO’s installation quality proved itself: clean terminations, properly labeled circuits, and tight panel layouts enabled rapid verification and a smooth transition into live operation.
The Result
ASBECO transformed a sprawling, aging control infrastructure into a clean, modernized physical system ready for high‑performance automation.
The outcome for the client:
- Reliable new enclosure systems across three elevations
- A cleanly executed power and I/O migration
- Physical infrastructure aligned with modern controls architecture
- A startup that ran smoothly thanks to precise workmanship
A Proven Installation Partner
This project demonstrates ASBECO’s strength in delivering complex industrial installation work with discipline, safety, and technical precision. From demolition to final commissioning support, ASBECO provided the field execution that made this modernization possible – turning a challenging multi-level upgrade into a seamless success.