Capability · Allen-Bradley rebuilds

Allen-Bradley PLC migrations, integrated end-to-end with mechanical.

Industrial control system retrofits — Allen-Bradley PLC migrations, with mechanical and controls integrated under one team. Restore productivity on aging assets without replacing the equipment your operation runs on.

When an Allen-Bradley platform hits end-of-life — spares on a six-week lead, support tickets going nowhere — the line keeps running on borrowed time until it doesn't. Kraytek reverse-engineers the original controls and mechanical scope side by side, re-platforms onto a current vendor stack, and ships the rebuilt machine under one crew, one schedule, one PO.

Rails, drives, and HMIs replaced end-to-end — same mechanical footprint, same operator interface language, current vendor platforms underneath. Spares lead time replaced with vendor-current platforms; the same asset re-validated against 21 CFR Part 11 + OSHA post-retrofit.

Talk to engineeringDownload scoping brief

Rockwell Automation Solution Partner · engagement with a current-vendor stack.

Scope of a rebuild

What a rebuild covers — and what you bring to walkdown.

Three deliberate scopes, drawn from Kraytek's engagement model. The boundary between customer and crew is drawn up front so the quote matches the work.

Typical scope

What gets rebuilt
Complete replacement of obsolete PLCs, drives, HMI, and instrumentation on existing assets. Mature platforms stay in service another decade; spare parts and support stay available.
  • PLC / DCS migration
  • Drive & servo upgrades
  • HMI / SCADA redesign
  • Field instrumentation

Delivered

What Kraytek owns
One procurement chain, one installation crew, one commissioning sign-off. You get today's spare-parts lead times and a documented asset your own team can service without us on the phone.
  • Mechanical teardown + reverse-engineering
  • Controls re-platform onto a current vendor stack
  • Re-assembly + commissioning under one crew
  • Documentation + spare-parts plan for the next decade
  • One procurement chain, one installation crew, one commissioning sign-off

Customer

What you bring
Walkdown access and what engineering reads to write the first scope. No asset images, no formal spec sheets — just the information a controls engineer needs to rank the problems.
  • On-site access during walkdown — mechanical condition, controls stack, I/O count, fault history, and the operator’s day-to-day pain
  • The asset name + line type (e.g. PLC upgrade, horizontal form-fill-seal, converting line)
  • A sentence or two on the symptom and what triggered the conversation

Case study

Allen-Bradley line-down to line-back-up — a rebuild case study.
A packaging line, line-down, on a controls stack past end-of-life.

See the BEFORE state, the rebuild scope, and the AFTER metrics on the same asset — measured against the new-line alternative.

Read the case study

Start the conversation

Talk to engineering about an Allen-Bradley rebuild.

Send the asset name, the controls stack, and the symptom. Engineering reads every submission — no sales triage, no script.

Project inquiry
Five fields. Engineering responds within one business day.

We respond within one business day. No triplicate vendor handoffs.

Prefer email?
Send engineering a note and we'll loop back within one business day.
Email engineeringkraytek-automation@polsia.app

For quick logistics (a capex number, a sample SOW, a vendor shortlist), the form is the fastest path — every question fields an answer.

For procurement-led introductions, please mention who on your team owns the spend in the "What are you trying to solve" box.

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