Automation obsolescence

At NIRAS, we help food and beverage manufacturers, distilleries, and industrial clients take control of this risk—by identifying vulnerabilities in their automation infrastructure and developing smart, phased solutions that protect operations today and prepare them for tomorrow.

What is automation obsolescence?

Automation obsolescence refers to the gradual ageing and eventual failure of the systems that keep manufacturing operations running. It includes not only PLCs and SCADA systems, but also the wider network of components that feed into them: control gear, safety circuits, sensors, motors, servers, software platforms, panel infrastructure, and cabling.

As technology advances and support lifecycles shorten, equipment that once functioned reliably can become a liability. Updates are no longer available. Spare parts become scarce. Cyber security threats increase. And when failure happens, it has a significant impact—bringing downtime, maintenance challenges, and production losses.

Obsolete or “legacy” systems might still be operational—but that doesn’t mean they’re safe, efficient, or future-ready. The pace of digitalisation in manufacturing means systems that are even 10 or 12 years old may now be unsupported or incompatible with modern production needs.

In one recent distillery project, our client was experiencing two automation-related failures per month, causing around six hours of downtime and approximately £75,000 in lost production every month. These are the kinds of hidden costs that turn “keeping things running” into a real business risk.

Expert guidance

NIRAS offers a full-service solution for managing automation obsolescence. Our Electrical, Control & Automation team starts with a deep dive into your systems, mapping out risks and opportunities. We conduct process surveys, create baseline condition reports, and assess the most vulnerable points in your system—whether it’s outdated firmware, unsupported software, poor cabling & containment, or control panels that no longer meet compliance standards.

Once we’ve established the scope, we work with you to develop a conceptual design and practical phasing plan, known as the Automation Risk Roadmap. This ensures that upgrades are rolled out logically—prioritising high-risk areas first and limiting disruption to your operations. From tender design and CAPEX planning to implementation, commissioning, and validation, we can provide a full end-to-end service or any key part in the project life cycle.

If you're concerned about automation obsolescence or want a clearer view of the risks within your current systems, our team is here to support. Get in touch to discuss how we can help you plan, prioritise, and deliver the upgrades needed to keep your operations running safely, efficiently, and without disruption.