Executive summary: Aging PLC-based control systems increase downtime risk and hide operational data, yet complete replacements are often unaffordable. A phased, risk-prioritized modernization—targeting CPUs, communication modules and selected I/O—combined with careful sourcing of refurbished or surplus parts can extend asset life, enable IIoT connectivity, and deliver measurable ROI without a large capital outlay. Introduction: the “Legacy”
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