Upgrade Your Converting Equipment with Intelligent, Safety-Focused Control Systems
At Blue Onyx Systems, we specialize in modernizing legacy converting machinery—like slitter rewinders, laminators, and flexographic presses—by integrating advanced control systems that enhance performance, safety, and compliance. Our retrofit solutions not only extend the useful life of your equipment but also bring it in line with today’s industry standards through safety-rated components, diagnostics, and scalable architectures.
With deep experience in the converting industry, our multidisciplinary engineering team delivers retrofit projects from concept through commissioning. Electrical engineers implement updated drive systems, smart safety controls, and modular I/O platforms. Mechanical teams assess and improve operator ergonomics and guarding, while our software developers ensure seamless integration with safety PLCs, HMIs, and plant-wide systems.
Whether you need to upgrade a single winder or retrofit an entire line, Blue Onyx Systems delivers engineered solutions that enhance uptime, ensure compliance, and protect your most valuable assets—your people and your production.
Flexographic Press Upgrades
CI Drive System Upgrades
The Blue Onyx Systems drive system upgrade has been designed to enable precise synchronization of press motors. This new level of control is combined with an updated operator interface to allow for supervisory, engineering, and remote diagnostics capabilities.
Choosing the Blue Onyx Systems CI drives upgrade facilitates:
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Increased Press Speed
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Decreased Changeover Times
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Increased Energy Efficiency
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Increased Supportability
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Elimination Of Obsolescence Concerns
Print Deck Positioning System
Deck adjustment can be a time consuming and laborious process. By modifying and upgrading the key components, procedures can be controlled much more easily for faster adjustment and more precise results.
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Independent & Coordinated Movement Of All Motors
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Higher Precision & More Repeatable Zero Referencing
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Simplified Calibration
Operator Interface Updates
Blue Onyx Systems operator interfaces are made to meet the needs of press operators to provide the most simple, easy, and effective control of their machines. Operator interface upgrades provide an easy way to expand control and maximize ease of use. Blue Onyx Systems can also upgrade the pendant control with new units that are equipped to:
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Manipulate Plate & Anilox Movement From A Safe-Zone
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Monitor Local Status & Control During Deck Calibration
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Be Moved Easily Through Use Of Its Magnetic Base
Winder Drive/Controls
At Blue Onyx Systems, we engineer custom drive control architectures specifically designed to modernize and optimize winder systems. Leveraging decades of application expertise, we deliver precise and efficient drive upgrades that enhance web handling, tension management, and safety. Our solutions support full integration and scalability for evolving production demands, including:
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Precision Tension and Torque Control
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Multi-motor Coordination and Dancer Positioning
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Regenerative Braking and Energy Management
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Drive Tuning for Roll Diameter Compensation
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Seamless Integration with Existing PLC and HMI Infrastructure
Slitter Rewinder Upgrades
Recharge your slitter rewinder equipment with an Blue Onyx Systems controls upgrade. By outfitting your machine with the latest in servo motors, drives, control and safety systems, Blue Onyx Systems provides a way avoid purchasing costly new equipment by maximizing your existing investment.
Blue Onyx Systems minimizes any machine downtime with fast installation and commissioning of the upgrade. We then assure long term success of the machine through and training and support that keep the slitter rewinder running well for its entire lifespan.
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Increased Web Speed
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Improved Web Tension Control
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Extended Expected Machine Lifetime
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Intuitive Operator Control
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Reduced Maintenance
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Increased Safety
Operator Interface Updates
Blue Onyx Systems operator interfaces are made to meet the needs of press operators to provide the most simple, easy, and effective control of their machines. Operator interface upgrades provide an easy way to expand control and maximize ease of use. Blue Onyx Systems can also upgrade the pendant control with new units that are equipped to:
-
Manipulate Plate & Anilox Movement From A Safe-Zone
-
Monitor Local Status & Control During Deck Calibration
-
Be Moved Easily Through Use Of Its Magnetic Base
Winder Drive/Controls
At Blue Onyx Systems, we engineer custom drive control architectures specifically designed to modernize and optimize winder systems. Leveraging decades of application expertise, we deliver precise and efficient drive upgrades that enhance web handling, tension management, and safety. Our solutions support full integration and scalability for evolving production demands, including:
-
Precision Tension and Torque Control
-
Multi-motor Coordination and Dancer Positioning
-
Regenerative Braking and Energy Management
-
Drive Tuning for Roll Diameter Compensation
-
Seamless Integration with Existing PLC and HMI Infrastructure
Laminator Upgrades
Upgrading your controls through Blue Onyx Systems can transform your existing machine into a low price, high production quality laminator unit. When assessing the decision to invest, a laminator cost-benefit analysis can yield some of the strongest engineering and business cases in the shop floor.
Blue Onyx Systems customers realize more than just the direct benefits of faster equipment. An upgraded laminator now becomes easier to support, easier to train on, and is on a unified communication bus that helps to future-proof the application. Don’t let your legacy equipment slow you down.
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Increased Web Speed
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Improved Web Tension Control
-
Extended Expected Machine Lifetime
-
Intuitive Operator Control
-
Reduced Maintenance
-
Increased Safety
Operator Interface Updates
Blue Onyx Systems operator interfaces are made to meet the needs of press operators to provide the most simple, easy, and effective control of their machines. Operator interface upgrades provide an easy way to expand control and maximize ease of use. Blue Onyx Systems can also upgrade the pendant control with new units that are equipped to:
-
Manipulate Plate & Anilox Movement From A Safe-Zone
-
Monitor Local Status & Control During Deck Calibration
-
Be Moved Easily Through Use Of Its Magnetic Base
Winder Drive/Controls
At Blue Onyx Systems, we engineer custom drive control architectures specifically designed to modernize and optimize winder systems. Leveraging decades of application expertise, we deliver precise and efficient drive upgrades that enhance web handling, tension management, and safety. Our solutions support full integration and scalability for evolving production demands, including:
-
Precision Tension and Torque Control
-
Multi-motor Coordination and Dancer Positioning
-
Regenerative Braking and Energy Management
-
Drive Tuning for Roll Diameter Compensation
-
Seamless Integration with Existing PLC and HMI Infrastructure
What could you possibly gain from an equipment control system upgrade?
Equipment Lifespan
A control system retrofit can significantly extend the operational lifespan of converting equipment by replacing obsolete components with modern, reliable technology. By upgrading drives, servo motors, and PLCs, older machines gain improved precision, diagnostic capabilities, and energy efficiency—often matching or exceeding the performance of new systems. This not only delays costly capital equipment replacement but also maximizes ROI from existing assets.
Lower Maintenance
A control system retrofit reduces maintenance costs by replacing outdated, failure-prone components with modern, more reliable technology. Advanced diagnostics, improved motion control, and streamlined wiring minimize unplanned downtime and simplify troubleshooting. This leads to fewer service calls, lower spare parts inventory, and more predictable maintenance schedules.
Uptime
A control system retrofit significantly boosts equipment uptime by eliminating obsolete components and enhancing system reliability. With modern motion controllers, real-time monitoring, and built-in fault detection, issues can be identified and resolved faster—often before they cause downtime. The result is smoother production, fewer interruptions, and greater overall equipment availability.
Production Rate
Upgrading to a modern control system allows for faster, more precise motion control—translating directly into higher production rates. Enhanced synchronization, tighter process control, and reduced cycle times help equipment run at optimal speeds without sacrificing quality. This increased efficiency enables you to meet higher demand with the same equipment footprint.
Increase Profit
A control system retrofit boosts your bottom line by enhancing operational efficiency, reducing downtime, and lowering maintenance costs, all of which contribute to higher throughput and less wasted time. With optimized production processes, you'll see a better return on investment through increased output, fewer machine failures, and improved resource management. Ultimately, the retrofit helps maximize profitability by ensuring equipment performs at its peak potential.
Channel: Converting Industry
