OLD → NEW | Wire Extruder Line System Upgrade

Upgrading a Wire Extruder Line for Improved Reliability, Quality and Efficiency

Not every production improvement requires the replacement of an entire machine.

In this wire extruder line upgrade, SA Power transformed an existing production asset by replacing obsolete automation and control technologies with a modern integrated system solution designed to improve reliability, quality, and operational efficiency.

The project centered on upgrading a legacy control environment that has become increasingly difficult to support. While the mechanical elements of the extruder line continued to provide value, the ageing automation infrastructure limited the long-term sustainability of the system.

By migrating from obsolete technologies to modern automation platforms, the line was given a new operational foundation while retaining the value of the existing production equipment.

The upgrade incorporated technologies from Emotron, Lenze, Sprint, Emerson and Vascat, with the complete solution designed, installed and commissioned by the SA Power team.

A key objective of the project was to improve system reliability. Legacy control systems often present challenges relating to maintainability, component availability, and long-term support. Replacing these technologies with modern solutions provides a more sustainable platform for ongoing production requirements.

The upgrade also enhanced the overall quality and consistency of the operation. Modern control technologies provide improved process management and greater control over critical production functions, helping to support stable and repeatable manufacturing performance.

Efficiency was another important outcome of the project. Through updated control architecture, improved system integration and modern automation hardware, the extruder line is better positioned to support production demands while reducing many of the limitations associated with obsolete technologies.

The completed system demonstrates the value of upgrading the automation layer of existing equipment. Rather than replacing a production asset that still performs its core function, the customer now benefits from modern control technology combined with proven machinery.

From legacy control cabinets and ageing automation hardware to a fully integrated modern control system, this project highlights how targeted automation upgrades can extend asset life, improve operational performance and prepare production systems for future requirements.

For SA Power, successful automation projects are not simply about installing new technology. They are about delivering practical engineering solutions that improve the way industrial operations perform.

SA Power – Powering Industrial Automation.