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Boost Productivity & Uptime with a Unified Control Platform

Is your legacy DCS system risking (or reducing) your productivity, revenue or market share? See 5 ways to deliver more with less…

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A bearded male wearing protective equipement looks at a tablet on the manufacturing floor in a factory.

Does your distributed control system still think it’s … 2011?

Managers: if you are operating a legacy distributed control system (DCS), reduced productivity is already a given.

A 2025 survey of over 500 U.S.-based IT professionals says 62% of organizations rely on legacy software systems. And analysts estimate up to 70% of IT budgets are spent on managing legacy systems.

Despite known security and performance risks, countless IT teams support outdated codebases, navigate end-of-life products or manage fragile integrations.

Finally. Here’s process and power control on a single platform

In today’s manufacturing landscape, reliable production is non-negotiable. So, Rockwell Automation created a unified power control platform to help solve the problems companies face when relying on legacy and fragmented process and power control systems.

By combining process, power and motor control in one architecture, you get a connected, intelligent system that simplifies operations, delivers real-time decision-making data and keeps your business moving. This combined core provides clear visibility to real-time production and energy data in one place, making your facility more efficient, productive and profitable.

A unified platform simplifies everything

desktop monitor with analytics

Replace independent power management system with a unified control platform

network connectivity

Unmodified Ethernet seamlessly connects and communicates all data

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Get real-time access to process & motor control device intelligence

Video
PlantPAx Differentiation Video Series: Process + Power

Struggling to integrate power and process in your production operations? PlantPAx, Rockwell Automation's distributed control system, seamlessly unifies power and process, simplifying your operations and maximizing performance.

Today’s industrial environment is more demanding than ever. Here are 5 ways to produce more with less…

When production systems are fragmented – operational risks increase. Troubleshooting takes longer, downtime costs soar and profitability suffers. A unified control platform introduces a proactive, insight-driven model that helps you stay ahead of problems.

Our industrial control system offers an integrated architecture that helps streamline system design and deliver real capital and operational savings. You can produce more with less.

1. Boost productivity and uptime with predictive operations
When power and process data converge, you gain early fault detection, predictive analytics, preventative maintenance, and automated corrective actions. It helps reduce unplanned downtime and troubleshooting costs

2. Faster recovery when issues arise
Operators instantly know what tripped, why it happened and whether it’s a power or process issue. Accurate root-cause isolation accelerates recovery time and keeps production on track. Core features in our unified power and control architecture help increase uptime and recovery through options such as Automatic Device Configuration

3. Consistency across every facility
Standardized control libraries, repeatable engineering and familiar HMIs create a seamless experience across sites – reducing training time and helping new operators perform like seasoned pros

4. Integrated motor control for maximum throughput
Deep integration with motor assets delivers faster startup, better load sharing, improved torque control and reduced energy consumption – with up to 75% less wiring and essential Ethernet/IP connectivity

5. Modernization without downtime
Upgrade with less risk. Our unified platform enables live migrations with little downtime and process impact – keeping critical services running while you modernize. Save up to 25% integration costs with digital technology

Our connected system combines process, power and motor control on a single platform. This helps manufacturers simplify design, testing and installation plus, reduce hardware, downtime, maintenance and energy costs

Unified data helps reduce downtime. Monitor and troubleshoot process, motor control and energy use with predictive analytics and preventive maintenance data. See the condition of your networked devices from any location.

The opportunity: Increase productivity and uptime

Boosting productivity and uptime takes more than modern hardware – it requires unifying your ecosystem so assets speak the same language.

Our unified control platform helps:

  • Deliver real-time predictive analytics to identify failures before they happen
  • Integrate energy and production data on one HMI
  • Reduce production, uptime and profit risk
  • Simplify and standardize operations across sites
  • Troubleshoot faster
  • Maximize throughput
  • Extend asset life

This is the future of resilient, high-performing industrial operations – where integration drives agility, efficiency and cost savings.

With the right technology in place, your process, power and motor control system can become a strategic advantage. Let us show you how.

Planning a Greenfield or Plant Expansion Project?
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Planning a Greenfield or Plant Expansion Project?

Combining process, power and motor control on a single platform helps accelerate your speed to market, uptime, energy savings and return on investment. 

Learn More

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What is a DCS distributed control system?

A DCS distributed control system is a computerized system to automate and manage large, complex industrial equipment and continuous production processes. It spreads control functions across multiple controllers, rather than using a single central computer.

Decentralized control technology offers high production reliability, redundacy and real-time system monitoring.

A distributed control system is especially valuable for 24-7 industries like manufacturing, chemical, power generation, wastewater, oil and gas production and processing.

A DCS system manages electronic components (such as programable logic controllers (PLCs), variable frequency drives (VFDs), sensors and HMIs) over a connected network to control motor speed, temperature, flow and pressure to maintain efficient and safer plant operations.

Published February 4, 2026

Topics: Accelerate Digital Transformation Optimize Production Industrial Automation & Control Process Solutions Smart Manufacturing Connection Devices Drives Distributed Control Systems Industrial Control Products Motor Control PlantPAx

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