PLC Alternative
Board-level architecture replacing standard PLC CPU modules in cost-sensitive OEM projects, reducing hardware BOM by 30–60%.
Industrial Automation Hardware Supplier
Replace Expensive PLC Hardware with Custom Industrial Control Boards
We help equipment manufacturers reduce controller cost by 30–60% while keeping industrial reliability. IdeatorTech delivers board-level alternatives for PLC logic control, communication, and edge processing — engineered for volume production.
- Reduce hardware cost for volume production
- Customize I/O, protocol and firmware by application
- Industrial-grade design for cabinet and factory environment
Protocol Flexibility
EtherCAT, CAN, RS485, Ethernet and mixed communication stacks for deterministic machine networks and integration.
Custom Engineering
From pin definition to firmware baseline — faster migration from legacy PLC platforms with full customization support.
PLC Replacement Value
Where We Create Measurable Advantage
Lower BOM Cost
Replace high-cost PLC hardware with application-specific controller boards. In batch production of 100+ units/year, our customers typically achieve 30–60% hardware cost reduction compared to branded PLC module configurations.
Faster Function Adaptation
Adjust communication protocols and control logic faster than closed PLC ecosystems. No vendor lock-in — our open architecture lets your R&D team iterate directly on the firmware and I/O configuration.
Compact Integration
Integrate controller function directly inside your equipment enclosure, reducing cabinet complexity, wiring cost and overall machine footprint for tighter installations.
Commercial Impact
Traditional PLC vs IdeatorTech Board Solution
| Dimension | Traditional PLC Route | IdeatorTech Board Route |
|---|---|---|
| Hardware Cost (Volume) | Higher module cost, limited room for BOM optimization. | ✅ Lower board-level cost with application-specific architecture. |
| Function Customization | Bound by vendor ecosystem and fixed module interfaces. | ✅ Flexible I/O, communication and firmware adaptation. |
| Integration Footprint | More cabinet space and wiring complexity. | ✅ Compact board integration inside your machine system. |
| Protocol Expansion | Additional modules may be needed for special protocols. | ✅ Protocol stack can be selected for your target architecture. |
| Product Differentiation | Common platform shared by many competitors. | ✅ Custom control platform aligned with your equipment strategy. |
Product Portfolio
Industrial Control Board Catalog
Resource Pages
Explore PLC Replacement by Scenario
By Industry
See migration priorities for machine builders, process equipment OEMs and smart factory projects across packaging, textile, and CNC industries.
By Protocol
Understand EtherCAT, CAN, RS485 and Ethernet selection for different control architectures and migration complexity.
By Controller Model
Compare STM32H7, EtherCAT F429 and F4/F1 options by performance, cost, and application target.
Cost Estimation Tool
Estimate annual savings when replacing PLC module route with board-level architecture for your production volume.
Migration Workflow
How We Replace PLC in Your Equipment
We map your current PLC I/O and control logic, then deliver a board-level alternative with validation support. This approach is designed for OEM migration, cost optimization and stable mass production.
- PLC Mapping: Review existing PLC function blocks, I/O map and communication interfaces.
- Board Selection or Customization: Choose standard board or customize for your machine platform.
- Firmware Adaptation: Build control baseline and communication layer for your application.
- Pilot Validation: Prototype integration and field tests before scaling to mass production.
FAQ
PLC Replacement Questions from OEM Teams
Can this replace Siemens/Omron PLC in production?
For many equipment-level applications, yes. We first map your logic, I/O and
communication requirements, then define migration scope. Our boards have been applied in packaging
machinery, textile equipment, and industrial gateways as direct replacements for branded PLC modules.
What information is needed for quotation?
Current PLC model, I/O count, protocol type, control cycle target and annual
quantity are the core input fields for RFQ. If you have an existing PLC program or I/O map, that helps us
estimate the migration scope and provide a more accurate quotation.
Do you support prototype-to-volume transition?
Yes. We support pilot validation, firmware adjustments and stable batch delivery for
long-term equipment programs. Our standard workflow includes prototype integration, field testing, design
refinement, and then scaling to volume production.
Which industries benefit most from PLC replacement?
High-volume OEMs with stable machine architectures see the strongest ROI: packaging
machinery, textile and process equipment, CNC machines, and smart manufacturing lines. Annual volumes of
50+ units typically make board-level control commercially compelling.
What is the typical migration timeline?
For standard board selection with firmware adaptation, typical timeline is 4–8 weeks
from requirement confirmation to pilot board delivery. Fully custom board design may take 8–12 weeks
including PCB design, prototype build, and initial validation.
Contact
Talk to Our Engineering Team
Company: IdeatorTech
Location: High-tech Zone, Qingdao, Shandong, China
Phone / WhatsApp: +86 186 7803 1316
Email: [email protected]
RFQ