Case study · Electronics
PLC replacement: up to 28× cheaper
An industrial machine controller rebuilt on Arduino-class hardware: same behaviour, a fraction of the cost, twice as fast to commission.
- Client
- Manufacturing client (anonymised)
- Published
- 10 May 2025
Challenge
A production line needed its controller replaced. The quoted PLC, including programming, wiring and licensing, came to roughly 28 times the cost of an equivalent microcontroller solution, with long lead times.
What we built
We mapped every input and output, replicated the machine’s logic in embedded C++, and built a custom I/O board with relay protection in a proper enclosure. The panel was wired, labelled and tested against the original behaviour before swap-in.
Result
The replacement cost a fraction of the PLC quote (up to 28× cheaper) and was commissioned twice as fast as the quoted option would have taken. The firmware is documented and version-controlled, so the client is never locked to a single vendor again.
Stack
Tunis based. Working with Tunisia, the Gulf and Europe.
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