Why Automation Matters in Used Equipment
The automation system is arguably the most important factor in determining the long-term value of used bottling equipment. A mechanically perfect machine with an obsolete PLC can require €40,000–€80,000 in migration costs.
PLC Platform Generations
| Platform | Era | Spares | Recommendation |
|---|---|---|---|
| Siemens S5 | 1980s–1999 | Extremely limited | Full migration required |
| Siemens S7-300 | 1994–2020 | Declining | Plan migration 3–5 years |
| Siemens S7-1500 | 2013–present | Available | No action needed |
| Allen-Bradley PLC-5 | 1987–2008 | Limited | Full migration required |
| Allen-Bradley ControlLogix | 1998–present | Available | No action needed |
HMI and Operator Interface Assessment
- Screen technology and dead spots
- Software version availability
- Backup availability
- Display size and resolution
- Communication with PLC
Source Code: The Hidden Value Factor
PLC source code availability is one of the most critical and most frequently overlooked factors when purchasing used equipment.
Migration Cost Estimation
| Machine Type | Simple | Complex |
|---|---|---|
| Single machine | €15,000–€30,000 | €30,000–€50,000 |
| Filler or blow moulder | €30,000–€60,000 | €60,000–€100,000 |
| Complete line | €80,000–€150,000 | €150,000–€250,000+ |
Frequently asked questions
What is the most common PLC platform in used bottling equipment?
Siemens S7-300 and S7-1500 are most common in European-built equipment. Allen-Bradley ControlLogix is prevalent in North American-built equipment.
How do I know if a PLC migration is needed?
If the machine uses Siemens S5, Allen-Bradley PLC-5, or any discontinued platform, migration should be planned.
Can I run a mixed-PLC line?
Yes, using OPC-UA or protocol gateways. However, it increases maintenance complexity.
How long does a PLC migration take?
2–4 weeks for a single machine to 8–16 weeks for a complete line.