Andis Company has completed a major controls upgrade of its vacuum heat treatment furnace system, reinforcing operational reliability and long-term production efficiency at its manufacturing facility in Wisconsin. The project involved modernization of the control architecture for the company’s ECM FLEX vacuum furnace, which is used for hardening critical components in Andis grooming products. The upgrade replaced the aging Siemens S7-300 processor and Profibus communication network with the latest S7-1500 series processor and Profinet communication technology.
The modernization initiative also incorporated remote input/output integration across the entire furnace system to improve connectivity, operational performance and long-term maintainability. ECM USA supported project planning, engineering and on-site execution, enabling the upgrade to be completed on schedule with minimal disruption to manufacturing operations.
The three-cell modular hardening furnace operates at temperatures of nearly 950 degrees Celsius and includes a 20-bar gas quench system along with automated loading and unloading functions. Installed approximately 15 years ago, the furnace replaced older molten salt bath systems and enabled cleaner heat-treatment processes with reduced component discoloration and lower post-processing requirements.
The furnace continues to play a central role in Andis Company’s production operations, supporting precision heat treatment processes essential for maintaining product durability and manufacturing quality standards. The controls modernization project was initiated after Siemens announced end-of-support timelines for key legacy control components. According to company officials, maintaining uninterrupted performance and operational reliability was a critical priority due to the furnace’s importance within day-to-day production activities.
Tom Hoffelder, Director of Manufacturing Support and Innovation at Andis Company, stated that the company worked closely with ECM USA to define the scope of the project and establish an execution plan that would allow modernization activities to proceed without impacting production schedules.
The upgrade focused on improving hardware reliability, simplifying future maintenance requirements and preserving operational throughput throughout installation and commissioning activities. Despite the extensive system modernization, the updated controls and human-machine interface were designed to remain familiar to operators, allowing the furnace to resume full-scale production immediately after commissioning without additional operator training.
Industry experts note that modernization of industrial automation systems has become increasingly important as manufacturers transition away from aging control platforms toward advanced digital communication and automation technologies. Upgraded systems can improve production reliability, reduce maintenance risks and enhance long-term operational efficiency while extending the lifecycle of critical manufacturing assets.
Andis Company continues to invest in advanced manufacturing technologies aimed at supporting production consistency, process optimization and operational resilience across its facilities. The successful completion of the furnace upgrade reflects the company’s ongoing commitment to maintaining reliable manufacturing infrastructure while adapting to evolving industrial automation standards.
