Capability · FAQ
The questions engineering hears most often about Allen-Bradley rebuilds, packaging line controls and integration, and OEM-orphaned control-system recovery. Each answer is drawn verbatim from the corresponding capability deep-dive.
Allen-Bradley rebuilds
What a typical rebuild covers, and how spares lead time is replaced.
A typical rebuild covers complete replacement of obsolete PLCs, drives, HMI / SCADA, and field instrumentation on existing assets — the canonical scope is PLC / DCS migration, drive & servo upgrades, HMI / SCADA redesign, and field instrumentation. Rails, drives, and HMIs are replaced end-to-end with the same mechanical footprint and the same operator-interface language your crew already runs. Spares lead time is replaced with vendor-current platforms; the same asset is re-validated against 21 CFR Part 11 + OSHA post-retrofit. Re-assembly and commissioning are signed off under one crew, one schedule, one PO.
See also: capability deep-dive · question 1 of 2
Kraytek engages with a current-vendor stack as a Rockwell Automation Solution Partner — re-platforming onto platforms still being published and still on the spare-parts shelf, so support tickets resolve and lead times come back down to 24h on common parts.
See also: capability deep-dive · question 2 of 2
Packaging lines
What happens at a packaging-line walkdown, and what the retrofit actually entails.
Audit. On-site walkdown of the line: controls stack, I/O count, fault history, and the operator's day-to-day pain. Output: a ranked problem list engineering reads to write the first scope. The walkdown is the boundary between customer and crew — what you bring (asset name, line type, the symptom) sets up the quote that follows.
See also: capability deep-dive · question 1 of 2
Four typical engagements — line-controls retrofit (PLC migration on form-fill-seal, converting, and web-handling lines, re-platformed onto a current vendor stack with the operator-interface language preserved), HMI recipe management (recipe stores re-keyed to current HMI/SCADA conventions with version history and change control), vision-inspection tie-in (inline vision systems integrated into the line PLC with reject logic, lot tracking, and rejection-cause analytics surfaced into the same HMI operators already read), and throughput optimization (bottleneck-grade instrumentation and drive tuning on the existing line, gains documented against the asset, not the spec sheet). All four are delivered under one crew, one schedule, one PO.
See also: capability deep-dive · question 2 of 2
OEM-orphaned recovery
Reverse-engineering, replacement-panel retrofit, and the cutover.
When the original vendor stops publishing firmware updates and the spare-controller shelf empties, the line sits on borrowed time — we capture the program logic, alarm hierarchy, and I/O map before the documentation itself goes cold. If the original prints, ladder, and HMI source have vanished, we reconstruct the documentation your maintenance team can actually read — current-vendor diagrams, I/O lists, and a narrative the next engineer can pick up. When the control panel itself is past its service life, the replacement-panel retrofit covers terminal blocks, wiring, and power distribution end-to-end, mechanical footprint preserved, operator-interface language preserved, current vendor stack underneath.
See also: capability deep-dive · question 1 of 2
Cutover with documentation handoff. Re-assembly, commissioning, and re-validation happen under one crew, one schedule, one PO — same mechanical footprint, same operator-interface language, current vendor stack underneath. The asset stays under your operation's control at every handoff: the documentation stays with you, so the next decade of service stays in-house.
See also: capability deep-dive · question 2 of 2
Engagement model
One crew, one schedule, one PO — and what stays with you at handoff.
One procurement chain, one installation crew, one commissioning sign-off. Every engagement — Allen-Bradley rebuilds, packaging-line controls and integration, OEM-orphaned recovery — ships mechanical and controls integrated under one team. The line stays under your operation's control at every handoff; the documentation stays with you, so the asset your own team can service without Kraytek on the phone.
See also: capability deep-dive · question 1 of 2
A documented asset your own team can service without us on the phone: current-vendor diagrams, I/O lists, program narrative, alarm hierarchy, and a spare-parts plan for the next decade. Re-validation against 21 CFR Part 11 / OSHA where applicable. No foreign ownership of the documentation, no separate commissioning contractor — the line stays under your operation's control at every handoff.
See also: capability deep-dive · question 2 of 2
Still have questions?
Send the asset name, the controls stack, and a sentence on the symptom. Engineering reads every submission — no sales triage, no script.
Capability deep-dives