Open-heart retrofit for one of europe’s largest dairies: From S5 to Plant iT V9.
It’s the long-awaited transformation to the next level. This software retrofit for one of our most loyal customers demonstrates how the modernization of a large dairy can be achieved not only efficiently but also with virtually no downtime. In the process, we sent the S5 controller—a true industrial dinosaur—into well-deserved retirement and, through a streamlined migration to a modern Plant iT V9 environment, ensured greater control, transparency, and safety in the process.
50
%
More redundancy
Initial situation
Legacy software that has evolved over time is reaching its limits
The retrofit involved a central unit area of the dairy through which key process steps are carried out and whose failure would have an immediate impact on the entire production process. The existing automation system consisted of a control system that had evolved over decades but was prone to errors, making maintenance, troubleshooting, and future scalability extremely difficult. This served as a strategic obstacle to the plant’s further development.
- Faulty and unreliable Siemens S5 controller with Interbus connection
- Many legacy issues and ad hoc solutions resulting from nearly three decades of operation
- Confusing program structures and incomplete documentation
- A growing shortage of personnel with S5 expertise
The challenge
In just 16 months, make the automation of the entire powertrain division ready for the coming decades without further shutting down the heart of production.
Clear objectives for the project
Modernization without significant production downtime
Replacement of the S5 and ProLeiT OSNT Software
Integration into the existing software and MES landscape
Restructured, clearly separated process areas
State-of-the-art safety technology that meets dairy industry standards
Improved maintainability and scalability
Solution
From 1.0 to Industry 4.0 in just 16 months
In a clearly defined and coordinated process, the outdated S5 control software from the 1990s was replaced by a future-proof Plant iT V9 control system. In the process, the software was thoroughly restructured, migrated to current hardware, and divided into separate process areas—resulting in significantly improved redundancy and transparency. Close monitoring of production ensured that fine-tuning and implementation could be carried out without disrupting day-to-day operations.
Advantages
The retrofit offers both operational and strategic benefits for operators and users.
Structured software
Clear assignment to process areas makes troubleshooting and adjustments easier.
Future-proof technology
Standardized components and modern Profinet infrastructure reduce inventory and simplify the procurement of replacement parts.
Improved maintainability
Safe operation of the systems, even for personnel without an S5 background.
Greater integration
Into the MES system and the existing IT infrastructure.
State-of-the-art safety technology and comprehensive documentation
Promote transparency and compliance.
Implementation with minimal downtime
Basically on the fly, with reliable project support.
automation excellence
Maximum transparency with maximum availability. Our modernization meets all the requirements that KRITIS companies place on their processes and infrastructure.
20% less interface load
through standardized structures
50% more redundancy
through clearly separated process areas
100% more user-friendliness
in visualization and user interface logic
1-second screen refresh rate
virtually in real time, reduced from 10 to 1 second
”Open-heart surgery a success! Together with our client and partners, we have successfully achieved an important milestone on the path to a smart dairy.
Jens FiebigProkurist und Projektleiter
Our partners
Strong Teamwork for a Successful Transformation
Conclusion
With the replacement of the old S5 and OSNT systems and the migration to Plant iT V9, the dairy’s core operations were brought up to the latest technological standards. The combination of structured software, modern Profinet infrastructure, and state-of-the-art safety technology reduces risks, simplifies maintenance, and increases efficiency throughout the entire process. At the same time, the new, unified software structure lays the foundation for further steps toward digitalization—from deeper MES integration to future big data applications.
