The situation
Sugar Australia’s silo cleaning loader, a radio-operated machine controlling proportional hydraulics, tilt switches, and proximity sensors, was running on an ageing Omron PLC. No program backup existed, which meant nobody could confirm what the controller was actually doing, let alone plan a safe upgrade path. KSG Electrical brought Beetle Engineering in to recover the existing logic.
Our approach
- Sourced the correct programming cable and software to establish a connection with the ageing Omron PLC.
- Extracted the existing program from the unit and confirmed it was a complete, readable backup.
- Provided KSG Electrical with the extracted program for their records.
- Quoted for the next phase: bench-testing the recovered logic and supplying a modern replacement controller with full I/O verification prior to site installation.
Outcome
The PLC program was successfully recovered, closing a gap where the site had no record of the loader’s control logic. KSG Electrical and Sugar Australia now have that documentation in hand, along with a quote to progress to a full controller replacement when they’re ready to proceed.