The Hidden Cost of Outdated PLCs
Outdated PLCs may seem reliable, but they often come with hidden costs in downtime, cybersecurity risks, and rising maintenance needs. Learn how identifying these issues early can save time, money, and stress.
Posted by
M.Abuaziza
Posted at
Process Optimization
Posted on
Aug 25, 2024
Introduction
Programmable Logic Controllers (PLCs) are the backbone of industrial automation. But just because a system is still running doesn’t mean it’s still reliable. In fact, aging PLCs could be silently draining your operation’s efficiency — and costing you far more than a timely upgrade would.
Here are five hidden risks that come with relying on outdated PLCs.
1. Unplanned Downtime
Legacy PLCs are more susceptible to unexpected failures — whether due to hardware degradation, memory faults, or unsupported software. Replacement parts can be difficult to source, causing costly downtime while waiting for delivery or third-party repairs.
2. Rising Maintenance Costs
The longer you delay an upgrade, the more time and resources are spent on workarounds and short-term fixes. Troubleshooting older PLCs often requires engineers familiar with outdated tools, and patching bugs becomes an ongoing burden.
3. Cybersecurity Exposure
Most legacy PLCs were never designed with cybersecurity in mind. They often lack encryption, authentication, and remote access security — making them a prime entry point for attacks on industrial networks. One breach can halt operations and trigger costly compliance issues.
4. Integration Barriers
Modern SCADA, HMI, and IIoT platforms rely on seamless data exchange. Old PLCs may use proprietary or deprecated communication protocols, limiting your ability to scale or connect to smart diagnostics, analytics, or remote access systems.
5. Reduced Vendor Support
Many older PLC models are now discontinued. That means no new firmware, no technical support, and limited community knowledge. You’re left exposed if something goes wrong — and even routine upgrades can become problematic.
Conclusion
Outdated PLCs often hide their true cost behind a façade of “if it’s not broken, don’t fix it.” But behind the scenes, they introduce risk, inefficiency, and rising costs. A proactive upgrade strategy ensures stability, improves performance, and sets the foundation for future automation.
