Future-ready automation at MASPEX – a seamless control system upgrade with DYNAMOTION
MASPEX Group, a leader in Poland’s FMCG sector, continues to invest in reliability and the development of its technical infrastructure. Upgrading one of its key production machines was a strategic step toward standardization and long-term operational continuity. The project was delivered by DYNAMOTION – a certified Schneider Electric partner and a specialist in packaging system migration.
Change was inevitable – the response was strategic
The decision to modernize was based on a detailed assessment of the plant’s equipment and evolving market conditions. With key components of the PacDrive M system being gradually phased out and serviceability becoming increasingly difficult, it became essential to take steps that would ensure the long-term stability and reliability of production. The goal was not only to replace discontinued parts with modern equivalents, but also to align the solution with the plant’s broader infrastructure - unifying components, simplifying maintenance, and enabling future development.
"Upgrading to PacDrive 3 is not only about hardware availability – it also provides access to up-to-date engineering tools, improved motion precision, and greater flexibility for expanding machine functionality.”
— Stanisław Zysnarski, Packaging Systems Engineer, DYNAMOTION
"Upgrading to PacDrive 3 is not only about hardware availability – it also provides access to up-to-date engineering tools, improved motion precision, and greater flexibility for expanding machine functionality.”Planning and preparation for the modernisation
Preparation began with identifying all machines in the facility operating on either the PacDrive M or PacDrive 3 platform.
The purpose of this audit was to select components not only compatible with the machine undergoing modernization, but also aligned with the solutions already used across the plant. This helped streamline the hardware architecture and simplify spare parts management and servicing.
The next step involved a detailed analysis of the planned control application migration. The team reviewed the program structure, firmware versions, and functional blocks in use. The newest and least-used machine was selected for the upgrade, enabling the recovery of reliable components to support the remaining units.
Implementation preparations included migrating the application to SoMachine Motion 4.41, building a test bench with the new controller and drives, and launching the configuration in a non-production environment. The program was fully tested and optimized before deployment. In parallel, updated electrical documentation was prepared to reflect changes in power circuits and safety systems.
We begin every modernization project by understanding the actual needs of the plant and adapting the technology to production requirements.
This approach works well not only during implementation, but also in everyday operation.
Source:DYNAMOTION
Modernization process – step by step
The modernization process began with replacing the C400 controller with an LMC-series unit and upgrading the integrated iSH motors to new ILM drives. The wiring was updated accordingly, and communication interfaces were adapted to fit the new system architecture.
The new control system topology illustrates the post-upgrade architecture: replacement of the C400 controller with an LMC Pro, transition to a SERCOS III network, and integration of a Lexium 62 power supply with communication module, as well as ILM drives connected via hybrid cables to DB-4 distribution boxes.
Source:DYNAMOTION
The modernization process was executed in line with the predefined implementation schedule, effectively minimizing machine downtime.
Thanks to the early migration of the control application and thorough bench testing of the new setup - including the LMC controller and ILM drives - the machine was restarted on the production line smoothly and without any issues.
During commissioning, timing discrepancies between the SERCOS III network and the legacy SERCOS II topology were identified, which affected synchronization precision.
Following detailed analysis, the DYNAMOTION engineering team fine-tuned critical motion parameters, restoring full system functionality and ensuring precise coordination across all axes.
Where improvements meet reality
The upgraded control system based on PacDrive 3 has improved the machine’s reliability, flexibility, and performance. The new configuration also simplifies integration with other equipment across the facility.
"The modernized machine runs reliably, and the new system allows for easier monitoring and faster maintenance response. It was also important for us that the selected components match those used in other lines—this helps us manage our spare parts inventory more efficiently.”
— Jakub Paździora, Maintenance Engineer, MASPEX Wadowice
"The modernized machine runs reliably, and the new system allows for easier monitoring and faster maintenance response. It was also important for us that the selected components match those used in other lines—this helps us manage our spare parts inventory more efficiently.” As part of the modernization, the power supply and protection circuits were upgraded to meet current standards, with all changes reflected in the updated technical documentation. The project was completed on schedule, without disrupting production continuity, and its positive effects are already visible in the machine’s daily operation.
DYNAMOTION – certified specialist in PacDrive migration
For our team, the modernization of a machine at the MASPEX facility was not just another technical project - it was proof that a well-planned migration of a control system can bring real operational and strategic value.
From the initial inventory and application analysis, through the setup of a testing environment, to the commissioning of the machine in its new architecture, the entire process was carried out in close collaboration with the client’s team.
As a result, the outcome was not only a modern and stable control system based on PacDrive 3, but also the unification of the technical infrastructure and long-term assurance of production continuity.
As a certified Schneider Electric partner, we have completed dozens of similar implementations, both in Poland and abroad. We treat each project individually, believing that the strength of modernization lies not only in technology itself, but above all in understanding the client’s needs, clear communication, and attention to detail.
If you have any questions, feel free to contact us:
DYNAMOTION Sp. z o.o.
ul. Feliksa Wrobela 5, 30-798 Kraków
info@dynamotion.pl
+12 306 73 90
Autor
Adrianna Arent
A graduate of the AGH University of Science and Technology in Kraków with a degree in Mechanical Engineering. Packaging Process Automation Engineer at DYNAMOTION. Responsible for service consulting, sales, and marketing.
E-mail: adrianna.arent@dynamotion.pl
Considering migrating from PacDrive M to PacDrive 3?
DYNAMOTION is a team that will guide you through the entire process – from audit to launch of the new system.
Please contact us:
Stanisław Zysnarski
Packaging Process Automation EngineerM: +48 12 306 73 97
Mateusz Biega
Packaging Process Automation Specialist
M: +48 697 760 155
E-mail: mateusz.biega@dynamotion.pl
