Control system upgrade: Smelting

September 2025 System Integration & Control Systems Design

Systems Automation & Management (SAM) recently completed a major control system upgrade in the smelting industry. The project was delivered on budget and achieved a positive ROI for the client.

The most significant challenge was that all hardware and software had to be upgraded during the limited maintenance shutdowns available to the smelter. To overcome this, SAM deployed its proprietary solution, ensuring the project could be completed with minimal risk and no disruption to operations.

A key element of the upgrade was SAM’s dual-mode PLC CPU X5/X7, capable of running both legacy and new software in parallel across old and new hardware simultaneously. This approach gave SAM the flexibility to switch between systems on demand, greatly reducing the usual risks of downtime and delays.

Looking ahead, SAM recommends that a thorough reverse engineering of existing software and a complete functional specification be finalised before project development, an approach that would further streamline future upgrades.

At the heart of this success is SAM’s engineering team, who are driven by pride and quality. Their philosophy is simple: never leave the site with anything less than the best.

Tel: +27 11 803 0570,[email protected],www.sam.co.za

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