(Legacy) SCADA Conversions
Make your production future-proof with risk-averse and (automated) SCADA upgrades.
Is your critical production process still running on an outdated SCADA system? Legacy software (such as systems running on Windows 7 or older, unsupported platforms) poses a ticking time bomb for your business continuity. Hardware fails, IT security risks increase, and expansions are nearly impossible.
Yet many companies postpone migration, fearing high costs, prolonged production downtime, and data loss. This is unnecessary. As an independent PLC and SCADA specialist, TECHNITION helps your organisation to safely, efficiently, and controlled migrate outdated systems to modern platforms.
The unique approach: automated conversions
Manually redrawing screens and typing tags one by one is not only time-consuming and costly, but also extremely error-prone. TECHNITION distinguishes itself by performing legacy migrations as automated as possible.
By using smart scripts, data extraction, and advanced import/export techniques, we transform the logic and visualisation of your old system to the new platform (for example, to AVEVA System Platform or Ignition SCADA). The main benefits:
- Significant Cost Savings: Up to several tens of percent fewer engineering hours compared to traditional, manual migration work.
- Minimal Human Errors: Because tags, alarms, and scripts are automatically converted, the chance of typing and interpretation errors is virtually zero.
- Faster Turnaround Time: A shorter engineering and testing process, resulting in less downtime for your factory.
Migrations in regulated industries
Migrating a SCADA system is more than an IT upgrade; it is an intervention in the heart of your production. Especially in sectors such as pharmaceuticals, food industry, and energy, the requirements regarding traceability are strict. TECHNITION has in-depth experience with conversions in these demanding environments and ensures that your new system immediately meets the strictest industry standards:
- Ensuring compliance according to GAMP (GMP) and 21 CFR Part 11 (such as electronic signatures and audit trails).
- Complete documentation and validation via the V-Model, including extensive FAT and SAT test protocols, so you can immediately demonstrate that the new system is reliable during an audit.
- Any restructuring of outdated code to modern, modular ISA-S88 standards during the migration.
The approach to a SCADA conversion
A safe migration requires a structured approach. TECHNITION guides the process from A to Z:
- Analysis & Reverse Engineering: We meticulously map the functionality of the old system. What needs to be transferred 1-to-1, and which functionalities can we modernise or improve directly?
- Data Extraction & Tooling: TECHNITION develops or configures the scripts to extract tags, alarm limits, scripts, and historical data from the legacy database.
- Automated Generation: The extracted data is converted and imported into the new SCADA or HMI platform.
- Testing & Validation: Extensive offline simulations and Factory Acceptance Tests (FAT) to ensure that the new system does exactly what the old one did – or better.
- Phased Commissioning (Shadowing): Where possible, we run the new system in parallel ('in the shadow') with the old system, for a seamless and risk-free transition without unnecessary production downtime.
Opt for a safe and smart transition
Are you no longer tied to your old brand and want to migrate to a completely new platform? Or do you want to upgrade to the latest version of your current supplier? Thanks to our brand-independent, broad expertise, we advise you honestly on the best-fitting solution for your factory.