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Distributed Control System Solutions

Transform your operations with our fit-for-purpose Modern DCS Solutions
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Process Solutions
    • Overview
    • Basic Batch Management
    • Basic Batch Management
    • Comprehensive Batch Management
    • Comprehensive Batch Management
  • Optimization
    • Overview
    • Safety Instrumented Systems
    • Safety Instrumented Systems
    • AADvance
    • AADvance
    • Trusted
    • Trusted
    • ControLogix SIL-2
    • ControLogix SIL-2
    • Logix SIS
    • Logix SIS
  • Services
    • Overview
    • DCS Migration
    • DCS Migration
    • PlantPAx DCS
    • PlantPAx DCS

Achieve Desired Business Outcomes

Your plant-wide control system is the heart and lifeblood of your operations. A Distributed Control System (DCS) that is intuitive to operate, easy to maintain, and secure by design is essential for achieving consistent, enterprise-wide performance. In a landscape where uptime, quality, and agility are non-negotiable, a modern and reliable DCS empowers manufacturers to meet evolving business goals—whether that means increasing throughput, reducing operational costs, or accelerating digital transformation.

By enabling real-time visibility, seamless integration, and proactive decision-making, a modern DCS becomes a catalyst for smarter operations and sustainable growth. It not only safeguards your production environment but also aligns plant-level performance with strategic enterprise objectives.

Our Modern DCS Solutions foster a resilient and agile culture focused on production optimization, continuous improvement, and operational efficiency. Whether you’re modernizing existing infrastructure, building greenfield facilities, or expanding operations, our fit-for-purpose solutions are designed to meet industry-specific demands and optimize your investment and support long-term growth.

Greenfield

Expansions

Migration

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Modern Design & Implementation for Greenfields

Distributed Control Systems (DCS) play a crucial role in modern manufacturing—especially in greenfield projects, where there’s an opportunity to design, integrate and implement state-of-the-art facilities from the ground up. Free from the constraints of legacy infrastructure, equipment, or processes, these projects empower teams to innovate, challenge assumptions, and reimagine productivity with a fresh perspective. Our industry experts are ready to guide you through every phase of your digital transformation journey, helping to identify the right solutions to set you up for long-term success.

Implementing a modern DCS in a greenfield project allows automation professionals to leverage cutting-edge technologies—creating a scalable, connected, and future-ready enterprise. This strategic approach not only boosts operational efficiency but also provides a competitive advantage in today’s rapidly evolving manufacturing landscape.

  • Comprehensive system integration and lifecycle support
  • End-to-end DCS design and implementation
  • Network and cybersecurity planning and design
  • Cabinet design and installation
  • Process and Power solutions
PlantPAx Distributed Control System The Modern DCS
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Brochure
PlantPAx Distributed Control System The Modern DCS

The PlantPAx® system, a modern DCS, is a key component of The Connected Enterprise®.

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Expanding an Existing Facility?

PlantPax Interactive
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PlantPax Interactive
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When planning to increase your facility's capacity, it’s common to discover that your current control system has limitations that require professional design and implementation. Whether you’re adding one new product line or twelve, expanding your control system involves numerous decisions around planning and installation.

Rockwell Automation can partner with you to assess your plant's current capabilities, explore opportunities for process expansion, design appropriate process and utility systems, and present tailored solutions aligned with your project goals—while helping you evaluate the pros and cons of each.

  • DCS assessment/Consulting services and FEL/ FEED evaluations
  • DCS design and implementation
  • Comprehensive system integration and lifecycle support

Ease Your Migration

As your manufacturing operations evolve, maintaining an outdated DCS can limit production flexibility, increase downtime risk, and reduce your ability to achieve enterprise-wide success. That’s why our Modern DCS solutions are designed not only for performance – but also for a low-risk transition.

We help you minimize downtime, reduce operational risk, and accelerate time-to-value with proven migration strategies. Our experts provide tools—such as I/O scanners, wiring harnesses, and database conversion utilities—to ease the migration process.

Whether you’re pursuing a phased approach or a full system replacement, our DCS migration solutions enable the integration of new technologies at your own pace—while keeping your production running smoothly. We help unify control systems so you can respond faster, streamline operations, and drive measurable gains in productivity and cost efficiency. With our deep industry expertise, you can achieve a more efficient and productive future, moving toward a more connected enterprise with integrated automation operations.

  • DCS assessment/consulting services
  • Front-end loading (FEL) / front-end engineering and design (FEED) evaluations
  • DCS architecture and infrastructure design and implementation
  • Turnkey or full system replacement (rip-and-replace) migration
  • Phased migration strategies that incorporate hardware, software, and engineering migration tools
  • Comprehensive system integration and lifecycle support
  • Network and cybersecurity planning and design
Legacy DCS Modernization Guide
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Brochure
Legacy DCS Modernization Guide

Enable a Connected Enterprise with a holistic approach to migration.

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Optimize Your Investment 

Automation System Optimization
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White Paper
Automation System Optimization

Achieve superior system performance after a DCS migration.

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Whether your DCS journey is focused on improving performance or unlocking new capabilities to future-proof your operations, we've got you covered. Maximize the value of your existing assets and get more from your investment with our tailored solutions.

Unlock the full potential of your DCS with our comprehensive suite of value-added enhancements and strategic assessments:

Optimization & Value Enhancement Services

  • Digital Value Accelerator
  • Cyber Risk Assessment

Advanced Process Control & Simulation

  • Advanced loop tuning
  • Advanced regulatory control
  • Optimization with APC/MPC (advanced process control/model predictive control)
  • Digital Twin Simulation
  • Emulation tools like FactoryTalk® Logix Echo

Unlock the Full Potential of Your Operations

Discover the measurable benefits of partnering with our expert team—streamlining processes, boosting efficiency, and driving sustainable growth.

Full Lifecycle Support

From FEL and design through DCS project implementation, execution, commissioning, and post-project support, we provide comprehensive lifecycle management while accommodating future changes and expansions.

Choosing the right delivery partner is critical. With our deep expertise, we’ve got your back to make sure your project is done right. Our efficient engineering and effective implementation help deliver your project on time and within budget.

Our Team
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  • Global Expertise: With extensive global experience, we efficiently manage multi-site deployments across diverse industries.
  • Certified Project Management: Our certified project managers deliver disciplined, on-time, and on-budget implementations using proven methodologies.
Performance & Adaptability
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  • Delivers reliable and scalable performance
  • Lowers operational costs by minimizing downtime, maintenance, and energy usage
  • Enables future innovation and market competitiveness
  • Scales with your business and adapts to evolving production needs
  • Provides real-time insights and predictive maintenance through advanced data collection and analytics
  • Accelerates project timelines through efficient design and engineering workflows
Seamless Integration
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  • Enables smooth integration with other systems and devices
  • Automates processes to reduce manual interventions and optimize resources for higher productivity
Increased Safety and Reduced Risk
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  • Enhances system reliability to minimize failures and unplanned downtime
  • Supports phased migrations for shorter outages and predictable outcomes
  • Delivers continuous operation with dual controllers and redundant backup systems
  • Integrates process safety through risk analysis, mitigation strategies, and certification
  • Complies with industry standards to maintain a safe and secure working environment
  • Maximizes system capabilities to optimize your project’s investment
Simplified Maintenance & Training
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  • Unified control systems simplify maintenance and reduce long-term costs
  • A common interface streamlines operator training, enabling faster adoption and fewer errors

Our Solutions in Action

Learn how we have helped our customers transform their operations with our fit-for-purpose Modern DCS Solutions

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Greenfields. Expansions. Migrations. Lifecycle Support.

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