Industrial revamping

Your machine
is worth keeping.

The enclosure, the mechanics, the motors and the cables stay. We replace what leaves you stranded: the controller nobody can repair anymore and the panel nobody can read.

Get your machine assessed How much downtime

We’ll also tell you when a revamp isn’t worth it.

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1994 before 2026 after

3D reconstruction: the control panel as it was in 1994, with its doors open. In the two bays, a rack-mounted PLC with block-style modules, rows of plug-in relays, contactors with their thermal overload relays, screw-cap fuse holders, two inverters of the period and wire bundles held with cable ties. At the bottom, the field terminal blocks. 3D reconstruction: the same panel in 2026, from the same viewpoint. In the two bays, covered wiring ducts, two drives, the modular PLC, the yellow safety relays, rows of circuit breakers and contactors. Enclosure, doors and field terminal blocks are the same.

Same enclosure, same motors, same terminal block. What changes is what leaves you stranded.

3D reconstruction of the same panel before and after a revamp: enclosure, doors, field cables and terminal block stay where they are.

Companies that have trusted us

The symptoms

Five things
we hear all the time.

Nobody calls us to “do a revamp”: they call about one of these. Behind each one there’s a specific technical cause, and it’s almost never the machine.

“Every now and then it stops and nobody knows why.”

The operator sees a code, not a cause. The alarms were written for whoever wrote the program, not for whoever is on shift at 3 a.m.

Alarms and states rewritten in plain language: what stopped, why, and what to check.

3D reconstruction: the operator panel of a 1994 control cabinet, with its membrane front and function keys. The green character display shows a single line: “ALLARME 047” (“alarm 047”).

“The panel is still the green one with the buttons.”

An unsupported operator panel, no spares left, and a backup that no computer today can open anymore.

A new panel with the same screens, plus the ones that were missing, and a backup you can still open in ten years.

“If that part goes, we’re down for two weeks.”

The component is discontinued: you can only find it used, with no warranty and no firm delivery date. And the day you need it, you need it now.

We replace the part that leaves you exposed with one still in production, and leave the rest alone.

3D reconstruction: the CPU of a 1994 PLC pulled out of its rack, standing on the bench, with the memory slot empty and the gold-plated bus connector in view. In front of it, the memory module that was taken out and a 3.5-inch floppy disk with “BACKUP PLC” handwritten on the label.

“The drawings don’t match anymore.”

Twenty years of changes made on site and never recorded. Whoever works on it goes by memory.

A survey of the actual panel and as-built drawings, terminal by terminal.

3D reconstruction: a yellowed folder of electrical drawings, open on the bench. The sheet in view is covered in corrections in red pen, blue pen and pencil: wires crossed out and redrawn, the notes “modificato” (“modified”), “tolto” (“removed”) and “vedi campo” (“see field”), a “NO!”, and a slip of graph paper taped on.

“Only Mario knows how to restart it.”

How it really works isn’t written down anywhere. It’s in the heads of the people who were there.

Documented logic and readable behavior: the line restarts even when he’s on vacation.

If you recognized even one of them, a revamp isn’t an investment to think about next year: it’s a risk you already have under your own roof.

The scope

What stays.
What changes.

An honest revamp doesn’t replace everything: it replaces what puts you at risk. This is how we think it through in front of every machine, item by item.

3D reconstruction: the 1994 control panel with its doors open, together with its field devices. On the floor to the left, a blue motor with its gearbox on a base; to the right, a photocell on a post. The cables run in a wire mesh cable tray under the plinth and come up from below to the terminal block.

3D reconstruction The panel before the work, with its field devices: the motor and its gearbox, the photocell on its post, the cables in the tray under the plinth.

  1. The field Stays.

    Frame and mechanics, motors, sensors, limit switches, wiring.

    If the mechanics are sound and the insulation holds, nothing is touched: only the wire tags are redone, the part that’s always missing. Motors almost always stay; sensors are tested one by one and only the faulty one is replaced.

  2. The terminal block Stays.

    It’s the boundary of the job: below it nothing changes, above it everything can.

  3. The control system Changes.

    PLC, I/O, network. Operator panel.

    It’s why you called us: unsupported means long downtime the day it fails. No spares left, unreadable backups, and diagnostics that don’t help whoever is on shift.

  4. The power panel Depends.

    If isolation and protection are in order, it’s upgraded. If the panel can no longer be read, it’s rebuilt: you gain years of maintenance. The drives almost always stay: they’re replaced only if the new controls can’t handle them, or if they’re as unsupported as the PLC.

  5. Safety Reviewed.

    Once the controls are opened up, safety functions are reviewed against today’s requirements, not those of when the machine was built.

The quote is decided on these five items. We write them down first, together with you: so you know what you’re buying, and what you’re not.

If the work substantially changes performance or safety, from January 20, 2027, it carries the manufacturer’s obligations, CE marking included (EU Machinery Regulation 2023/1230). If that applies, you’ll know before we start.

Downtime

The line stops
only at the end.

It’s the first question we get: “How long will my line be down?” The answer depends on how much work we can move out of the shutdown. Almost all of it can be.

Line running · weeks

  • Survey with the plant running. We read the machine while it works, without touching it.

  • Drawings and I/O list rebuilt. Whatever is missing gets redrawn beforehand, not with the line down.

  • New panel wired and tested in Mesero. It arrives already tested. How we test it

  • Software rewritten and bench-tested. On simulated signals, before it ever sees the line.

Line down

The window is set around your production calendar. A weekend, a scheduled shutdown, a campaign changeover.

The proportions change from machine to machine. The rule doesn’t: anything that can be done while the line runs gets done first.

During the shutdown

What’s left is only what can’t be done at any other time.

  1. Out with the old. Every wire photographed and tagged before it comes off.

  2. Install and reconnect. The terminal block is the same: every conductor goes back where it was.

  3. I/O check. Every signal tested one by one, before the process gets the go-ahead.

  4. Restart with real material. Running isn’t enough: it has to produce, at the right rate, with the people who run it.

The survey

Nothing is left
in writing.

The machine builder is gone, the drawings stopped at day one, the program sits on media nothing can read. It happens almost every time and it’s nobody’s fault: that’s where the revamp begins.

3D reconstruction: a 1994 field terminal block, twenty ivory screw terminals. Half of the old wires already carry the new wire tag, white and printed; the other half still have the faded yellow collars. Beside it, on a clipboard, the survey sheet headed “RILIEVO MORSETTIERA” (“terminal block survey”), filled in by pen up to terminal 10: device tag, signal and direction. A pen lies on top.

We read the panel, not the paperwork.

Terminal block, wire tags, cross-sections, protection devices. The documents get compared afterward: when they don’t match, the panel wins.

We rebuild the signal list.

Every input and every output with its address, its terminal and what it actually drives in the field. It’s the document everything else is built on.

We back up what’s there, before touching it.

Program, drive parameters, recipes, operator screens. Even if the PLC is being replaced: today it’s the only description of how the machine works.

We write down what the machine does.

Sequences, interlocks, safety conditions, changeover. With the people who use it every day, not just the ones who bought it.

The drawings that come out of the survey are the same ones we draw for new plants: see how they’re made.

First we write down what’s there.
Then we decide what to change.

Plan B

What if it won’t
restart on Monday?

It’s the question nobody asks out loud, and the one that holds revamps back for years. It has a technical answer, and it’s settled before we start.

3D reconstruction: the 1994 PLC rack removed in one piece, standing on the bench, with power supply, CPU and modules in place. The front connectors are still plugged in, each cut wire carries its own tag, and a label tied on with string reads, by hand, “DA CONSERVARE” (“keep”) and, below, “ricollegabile” (“can be reconnected”).

We don’t scrap
the old panel.

It stays at your plant, complete and ready to reconnect, for as long as we agree. Until the line has produced for days at the right rate, stepping back is still possible.

Nothing is touched until it’s backed up.

What was backed up during the survey, plus a photo of every terminal block as it was.

We disconnect only what we can reconnect.

Every conductor is photographed and tagged before it comes off. Going back isn’t something to improvise on the shop floor: it’s a procedure that already exists.

Nobody buys a revamp because they feel like changing the PLC: they buy it when the risk of breaking down becomes bigger than the risk of stepping in. Plan B is there to tip that balance.

Service

Nobody vanishes
afterward.

The part you don’t see in the quote: what you have a month later, when the line is back in production and the first changeover comes.

What we installed, we stand behind.

One contact for the panel, the hardware and the software: if something goes wrong, it’s not up to you to work out whose fault it is.

The first year of support is included.

Call whenever you need to, without wondering what the question will cost.

We always answer.

For anyone who has bought from us, every day: +39 02 97289083.

If the plant has secure, authorized remote access, from Mesero we see the same screen your operator sees: many checks take half an hour instead of a site visit. How our remote support works

First step

Just the nameplate
and two photos.

Send us a photo of the PLC nameplate and one of the open panel. We’ll tell you whether that machine can be upgraded, what can be kept, what can’t, and how much downtime it really takes.

Get your machine assessed

An engineer reads it, and the first reply comes within 1–2 business days.

3D reconstruction: the aluminum nameplate on the power supply of a 1994 PLC, with the fields “TIPO” (“type”), “N°” (serial number) and “ANNO” (“year”) 1994, and the voltage 24 V DC. Beside it, lying on the bench, a phone with the open panel on its screen.

Down right now and can’t find the spare part? Call +39 02 97289083: that’s when it pays to skip the form. And if we built the machine and you need drawings or backups, we’ll pull them from our archive.