When control systems begin showing their age, many organizations assume a complete replacement is the only option. In reality, that isn’t always the case. Sometimes, industrial control panel upgrades are the answer.
Across Canada and the United States, manufacturers, utilities, municipalities, and industrial facilities are finding that control panel upgrades can often deliver many of the same benefits as a full replacement. However, upgrades come at a lower cost and with less disruption to operations.
Through strategic modernization, control panel retrofit projects, and phased upgrades, organizations can improve reliability, address component obsolescence, and prepare for future growth while continuing to leverage existing infrastructure.
The challenge is knowing when an upgrade makes sense, when a full replacement is necessary, and how to make decisions that support long-term operational goals.
We have interviewed Gary Jakob, Vice President at Keltour, about industrial control panel upgrades, control panel retrofitting strategies, and why taking a long-term view often leads to better outcomes than focusing solely on the immediate project.
Q: Why Is Full Replacement Not Always The Best Solution For Aging Control Systems?
When people see aging equipment, they often assume everything needs to be replaced. In many cases, that’s not true.
We regularly see systems where the process is still working well and the infrastructure has plenty of life left in it. Usually, the issue is obsolete components or limitations in the existing controls. An upgrade can address those areas without the cost and disruption of replacing the entire system. The goal is to improve what needs improving while getting the most value out of what’s already there.
Q: What Are The Biggest Advantages Of Modernizing An Existing Control Panel Rather Than Replacing It Entirely?
One of the biggest advantages is that modernization allows businesses and organizations to improve reliability and functionality while reducing operational disruption.
A control panel retrofit is often more efficient than a full replacement because you’re building on an existing system. You don’t have to start from the ground up. It can also help reduce costs when you’re trying to update obsolete components and improve system performance. It also helps with scalability.
We completed a retrofit project for a coffee manufacturing customer operating multiple grinding machines. The existing control system was built on an older platform that was no longer supported by the manufacturer, and replacement parts had become increasingly difficult to obtain.
Accurate drawings and a clear understanding of the existing system were key to the project’s success. With the right documentation in place, we were able to engineer a retrofit solution and conversion kit that supported a smooth move from the legacy platform to a modern control system.
Because the planning was done upfront, the installation had minimal production impact and allowed for a quick platform swap with little to no downtime.
Here’s an example of a new retrofit PLC cabinet (installed onsite) with a process application:
Here was the old PLC system:
Q: Many Companies Focus Heavily On Price. Why Can The Lowest Quote End Up Costing More?
While cost is always an important consideration, it’s important to look beyond the initial project price. While the lowest quote may work for the immediate requirements, it doesn’t include long-term support, documentation, future upgrades, or component availability.
We’ve worked with organizations that focused primarily on upfront cost. They ultimately reach out again because of maintenance challenges, troubleshooting, or system modifications. Those issues can outweigh short-term savings.
Our recommendation when looking at industrial control panel upgrades is to consider the total lifecycle cost of the system. In many cases, it’s years later that you realize the total cost of the modernization.
Q: Why Is Understanding A Customer’s Operational History Important During Modernization Projects?
When we’ve supported a customer over several years, we have a better understanding of their processes, operating requirements, and the history of their systems. That context helps us provide better recommendations and often leads to more efficient project execution.
Rather than approaching every project as a new challenge, we’re able to build on previous experience. Our recommendations align with the customer’s long-term objectives.
Q: How Can Organizations Determine Whether An Upgrade Or Full Replacement Is The Better Option?
It starts with evaluating the condition of the existing system and understanding long-term goals.
Sometimes a full replacement is the right decision. This is often the best option when an existing infrastructure can no longer support operational requirements or if the system has reached the end of its useful life.
However, many facilities discover that a targeted modernization strategy can fix their challenges while keeping a big portion of their existing investment.
Our approach is to evaluate the system as a whole and identify the areas creating the greatest risk or inefficiency. We then determine where upgrades can deliver real improvements. That allows our clients to make informed decisions based on long-term value rather than assumptions.
Q. What Should Be Reviewed Before Starting A Control Panel Retrofit Or Modernization Project?
Before starting any retrofit or modernization project, the first thing we look at is whether the existing system is fully understood. If drawings are outdated or incomplete, additional site mapping may be needed to reduce risk and avoid surprises later in the project.
It’s also important to consider both the current platform and future needs. Technology has improved significantly over the years. Newer systems often have better diagnostics, remote access, cybersecurity, and ease of maintenance.
It doesn’t matter if it’s a retrofit or a full replacement. In both cases, the solution should support today’s needs and future growth.
Q: What Questions Should Organizations Ask Before Choosing An Engineering Firm or Control Panel Manufacturer?
Businesses should look at several things before choosing a control panel manufacturer or engineering firm. Many manufacturers can build and design a panel. But the difference often comes down to the level of ongoing support and expertise they provide throughout the lifecycle of the system. This is something we excel at.
Keltour has extensive experience retrofitting control panels for process control and utility brownfield projects. We work with leading utilities and manufacturers, providing complete design, build, and integration solutions.
Our approach starts with understanding the existing system to reduce risk and support efficient project execution. To help achieve this, we offer a range of front-end engineering and site mapping services, including:
- LiDAR-based reverse engineering and as-built documentation
- Layout drawings
- Tray and conduit layouts
- Equipment configuration
- AC/DC system calculations
- Single line drawings
- Three line drawings
- Grounding studies
- AIS & GIS station design
- Full construction 3D simulation
- PLC programming
- GA, BOMS, CWDS
- FAT/SAT
- Safety Clearances
- Outage plans
These capabilities allow us to accurately capture existing conditions, improve design coordination, and support constructability from early engineering through to field execution, resulting in safer, faster, and more predictable project delivery.
We always recommend reaching out to discuss the required inputs to get started.
Q: What Advice Would You Give To Organizations Planning Industrial Control Panel Upgrades?
I encourage companies to look beyond the immediate upgrade requirements and think about their long-term goals. A successful upgrade should do more than solve a current problem. It should also support future growth, improve reliability, and provide flexibility for potential operational changes.
It doesn’t matter if the project involves a targeted control panel retrofit or a broader modernization initiative. Taking a long-term view will generally result in better outcomes.
The most effective projects we’ve worked on are those where technology decisions align with the organization’s overall operational strategy.
Industrial Control Panel Upgrades That Deliver Long-Term Value
Industrial control panel upgrades are often a practical alternative to full system replacement. Modernizing critical components, improving system capabilities, and addressing obsolescence concerns can extend the life of existing assets while preparing for future growth.
At Keltour Controls, every control panel retrofit and modernization project is approached with a long-term perspective. We combine technical expertise with ongoing support and a commitment to helping customers maximize the value of their systems. Keltour supports organizations across Canada and the United States through every stage of the control system lifecycle.
Is it time for control panel upgrades for your business? Contact Keltour today — our team is ready to provide retrofit solutions and support your industrial control panel upgrades.
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