10 Legacy Automation Components Still Driving Industry in 2025
While Industry 4.0 and smart factories dominate headlines, countless manufacturing facilities continue relying on proven legacy equipment. These robust systems form the backbone of global production, offering reliability, serviceability, and familiarity that newer technologies haven't fully replaced. Here are ten legacy automation parts maintaining strong demand in 2025.
1. Allen-Bradley SLC 500 PLCs: The North American Workhorse
For decades, SLC 500 PLCs have controlled North American manufacturing. Their modular I/O systems and reliable processors enable easy maintenance and expansion. Consequently, numerous packaging, bottling, and material handling lines still operate on this trusted platform.
2. Siemens S7-300 Controllers: European Industrial Backbone
Siemens S7-300 controllers remain Europe's industrial foundation after twenty-plus years. Their stability and compatibility across programming environments make them indispensable. Many original equipment manufacturers and process plants gradually transition to S7-1500 systems while maintaining S7-300 installations.
3. Yaskawa SGDH Servo Drives: Precision Motion Specialists
Yaskawa's Sigma-II series drives deliver exceptional motion control with high-resolution feedback. These units power robotics, CNC equipment, and precision placement machines. Their smooth torque performance and reliability often outweigh networking capabilities for many applications.
4. Mitsubishi FX2N PLCs: Compact Machine Control Solutions
Mitsubishi FX2N PLCs provide durable, compact control for original equipment machinery worldwide. Their straightforward programming and reliable input/output performance make them ideal for small machine control and sequential processes.
5. GE FANUC Series 90-30: Infrastructure Control Mainstay
GE FANUC Series 90-30 systems continue serving utilities, water treatment plants, and critical infrastructure. Their modular design, communication options, and robust programming platform support municipal and industrial retrofit projects effectively.
6. Omron C200H Series PLCs: Assembly Line Champions
Omron C200H PLCs operate numerous sensor-intensive assembly and packaging systems. These controllers offer rapid input response times and straightforward programming. Many older conveyor and pick-and-place cells still depend on their dependable performance.
7. Schneider Electric ATV31 Drives: Rugged Power Management
Schneider Electric ATV31 drives provide robust, compact motor control solutions. Despite newer models, many facilities maintain ATV31 units for their intuitive parameter configuration and compatibility with established networks like Modbus and CANopen.
8. FANUC Alpha Servo Systems: CNC and Robotics Precision
FANUC Alpha servo motors and amplifiers deliver exceptional precision for legacy CNC equipment and robotic systems. Their high-torque response and accurate feedback make them preferred for global milling, turning, and positioning applications.
9. ABB ACS300 Drives: Simple and Reliable Motor Control
ABB ACS300 variable frequency drives offer straightforward operation and durable construction. These drives remain common in HVAC, conveyor, and mixing applications where reliability surpasses the need for advanced connectivity features.
10. Allen-Bradley PanelView Standard HMIs: Operator Interface Classics
Allen-Bradley PanelView Standard human-machine interfaces provide clear displays and responsive operation. Their simplicity, compact dimensions, and parts availability make them popular for retrofit projects despite newer HMI models entering the market.
Why Legacy Components Remain Essential
Complete control system replacement involves significant expense and operational risk. Therefore, maintaining existing systems with proven components often represents the most practical approach. Legacy parts enable facilities to extend equipment life while planning strategic upgrades.
Moreover, maintenance teams possess extensive knowledge of these systems. Their familiarity with wiring, programming, and troubleshooting reduces training requirements and accelerates repair processes. This operational experience provides tangible cost savings and minimized downtime.
Industry Perspective: Balancing Legacy and Innovation
From our industry experience, the gradual transition approach proves most effective for many manufacturers. Complete system overhauls require substantial capital investment and operational disruption. Instead, strategically replacing components while maintaining core infrastructure often delivers optimal results.
We observe that facilities combining legacy reliability with targeted technology upgrades achieve the best operational outcomes. This balanced approach maintains production continuity while incorporating modern capabilities where they provide maximum benefit.
Practical Application Scenarios
Bottling Plant Modernization: A beverage company maintained SLC 500 PLCs while adding modern sensors and data collection. This approach preserved their control investment while gaining production analytics.
Automotive Assembly: An automotive manufacturer kept Omron C200H PLCs operational while integrating new safety systems. This strategy maintained production uptime during phased improvements.
Frequently Asked Questions
Why do companies continue using legacy automation components?
Legacy components offer proven reliability, maintenance familiarity, and cost-effectiveness. Replacing entire systems involves significant expense and operational disruption.
Are legacy automation parts still manufactured?
Original manufacturers often discontinue production, but specialized suppliers provide refurbished and tested components with warranties.
How long can legacy automation systems remain operational?
With proper maintenance and component sourcing, legacy systems can operate reliably for decades. Many installations continue performing well beyond their expected service life.
What are the risks of using legacy automation equipment?
Potential challenges include component availability, cybersecurity limitations, and difficulty finding technicians with appropriate expertise.
When should companies consider upgrading from legacy systems?
Upgrade consideration becomes necessary when maintenance costs escalate, replacement parts become scarce, or operational requirements exceed system capabilities.
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