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CASE STUDY

MK2 Backfold Servo Upgrade

Allen-Bradley Kinetix Servo Upgrade Restoring 30,000 Carton/Hr Throughput on a Paperboard Packaging Line

The Challenge

A high-volume paperboard packaging line faced unacceptable downtime risk from end-of-life servo hardware with no vendor support — requiring a full motion control replacement alongside an electrical infrastructure upgrade.

• End-of-life servo drives and motors with no current vendor support, creating spare parts scarcity and unacceptable downtime risk on a high-throughput production line
• Outdated motion control architecture unable to meet the precision and speed demands of modern carton-forming operations
• Existing 240V, 3-phase power infrastructure incompatible with replacement servo hardware requiring a clean 480V supply — necessitating an electrical infrastructure upgrade alongside the controls replacement
• No modern operator interface, limiting operators' ability to monitor servo status, adjust parameters, or diagnose faults without specialized knowledge of the legacy system

The Solution

Logic Control Systems replaced the legacy servo system with a current-generation Allen-Bradley ControlLogix PLC, Kinetix servo drives, SERCOS motion network, and PanelView Plus HMI — along with a 480V electrical infrastructure upgrade to support the new hardware.

Electrical Infrastructure Upgrade

LCS coordinated the installation of a new 480V, 3-phase electrical supply to the MK2 Backfold machine, providing the clean power required by the Kinetix servo drives. This infrastructure work was completed in parallel with the controls replacement to minimize production downtime.

Control System

The new control system centers on an Allen-Bradley ControlLogix PLC communicating with two Kinetix servo drives over a SERCOS motion network. The SERCOS network provides high-speed, deterministic servo synchronization suited to the demands of high-volume carton forming. A PanelView Plus HMI gives operators clear visibility into servo status and fault conditions.

Commissioning

LCS performed full on-site commissioning:

• Electrical I/O checkout — verifying all wiring, drive connections, and safety circuits against the AutoCAD schematics
• SERCOS network validation — confirming drive discovery, axis configuration, and real-time communication between the ControlLogix and Kinetix drives
• Servo tuning — velocity and position loop tuning for both axes to achieve target motion profiles at full production speed
• Motion sequence testing — step-by-step verification of the backfold cycle, including timing, position targets, and fault response behavior
• HMI screen walkthrough with operators, covering normal operation, alarm acknowledgment, and parameter access
• Operational training for client personnel on the new control system, covering startup procedures, routine operation, and basic troubleshooting

Legacy end-of-life servo system replaced with a current-generation Allen-Bradley platform — restoring full 30,000 carton/hr throughput and eliminating spare parts risk.

Technology at a Glance

Results & Impact

• Legacy end-of-life servo system replaced with a current-generation Allen-Bradley platform, eliminating spare parts risk and restoring vendor support coverage
• Servo motors and drives sized and commissioned for 30,000 cartons per hour, meeting the line's full design throughput requirement
• SERCOS motion network provides high-speed, deterministic servo synchronization suited to the demands of high-volume carton forming
• PanelView Plus HMI gives operators clear visibility into servo status and fault conditions, reducing reliance on specialized legacy system knowledge
• New AutoCAD electrical schematics delivered with the panel provide accurate as-built documentation for future maintenance and troubleshooting
• Standardized Allen-Bradley platform aligns the MK2 Backfold controls with the broader Allen-Bradley ecosystem, simplifying cross-training and spares management

About Logic Control Systems

Logic Control Systems (LCS) is a Texas-based industrial automation integrator specializing in PLC programming, SCADA/HMI development, process control, electrical panel fabrication, commissioning, and remote automation maintenance. LCS serves clients across the U.S. in industries including food processing, fabrication, chemical, oil and gas, pharmaceutical, and water/wastewater.

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