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Client: Leading UK Metals Manufacturer
Client Type: End user
Industry: Metals
Location: UK
Scope: Full turnkey upgrade of legacy drives, PLCs, SCADA and safety systems, including robotic integration
Obsolete equipment replaced with modern, supported technology
Improved operator safety through advanced guarding and access control
Enhanced efficiency and production output via automation and robotics
Increased reliability and consistency across the control system
PUWER compliance achieved with modern safety architecture
A leading UK metals manufacturer faced increasing risks from hardware obsolescence, operator safety concerns, and limited spare parts availability on one of its major production lines.
The legacy drives, PLC and safety control system had reached end-of-life, resulting in reduced reliability, restricted flexibility, and poor machine access management — all contributing to potential safety and downtime risks.
To secure long-term reliability, meet modern safety standards, and boost productivity, the manufacturer required a turnkey control system upgrade, including core-handling industrial robots to automate key material-handling tasks.
iconsys delivered a comprehensive turnkey modernisation covering the full scope of electrical, control, automation and safety systems, from concept and design through installation and commissioning.
1. Drive, Control and Safety System Upgrade
The project included the installation of new DC drives, Siemens S7 Safety PLCs, ET 200 remote I/O, and a multi-screen WinCC SCADA system.
These upgrades provided greater diagnostic capability, faster setup, and an improved operator interface.
A Siemens Safe Architecture was implemented, using ProfiNet/ProfiSafe communications across drives and safety systems for seamless integration and enhanced reliability.
iconsys also modified the existing control panels, retaining enclosures while replacing backplates and internal components — a method that reduced installation time and minimised production disruption.
2. Functional Safety and Access Control
Following the client’s risk assessment, iconsys implemented a robust safety design to achieve PUWER compliance.
This included fixed guarding, controlled access zones, and interlocking systems using a Fortress AmGard safety gate solution, connected via ProfiNet/ProfiSafe for dependable communication and control.
The new architecture significantly enhanced operator safety and reduced risks associated with maintenance and manual intervention.
3. Robotic Core Handling Integration
Two outdated and unreliable core loaders were replaced with ABB IRB industrial robots, equipped with custom-designed end-of-arm tooling (EOAT) and a Cognex vision system.
The robots now perform automated core handling, checking core quality, dimensions and alignment to meet payload, reach and cycle time requirements.
Virtual simulations validated accuracy and performance during design, ensuring smooth integration with the new control and safety systems.
4. Turnkey Delivery & Support
iconsys managed the complete electrical and mechanical installation, providing 24/7 standby support throughout commissioning.
By combining automation, robotics, and functional safety expertise, iconsys delivered a fully integrated solution that:
Improved system availability
Enhanced safety and quality
Increased efficiency and throughput
The project exceeded client expectations, providing a future-proofed automation platform for ongoing productivity and process improvement.
Obsolescence eliminated through the replacement of legacy systems
Operator safety enhanced, achieving PUWER compliance
Production efficiency and throughput increased via robotics and automation
Improved reliability and diagnostics using modern Siemens technology
Reduced downtime through efficient installation and system re-use
The client selected iconsys for its proven ability to deliver complex turnkey modernisation projects that combine safety compliance, automation integration, and robotic expertise.
Our end-to-end project delivery, from safety design and risk assessment through to final commissioning, ensured the production line achieved new standards of safety, reliability and performance.
This project demonstrates iconsys’s capability to transform legacy manufacturing assets into efficient, compliant, and digitally enabled operations that meet the evolving needs of modern industry.
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