By 2024, the recycling company’s operations had outgrown its aging control systems. With 28 sites spread across Europe, each running on siloed legacy technology, the business struggled to connect equipment, vehicles, and plants into a single view. Control rooms relied on outdated hardware with limited integration capabilities, making it impossible to introduce predictive maintenance, automate reporting, or scale securely to the cloud. These technology and operational challenges were slowing growth, raising costs, and exposing the business to rising risks; transformation was no longer optional, it was essential.
The Challenge:
The company’s control room systems were based on outdated, proprietary technologies that:
• Prevented full connectivity between its 28 sites.
• Lacked integration with equipment, vehicles, and plant machinery.
• Offered limited monitoring and maintenance capabilities.
• Posed increasing security risks due to outdated frameworks.
As the business continued to grow, it needed to modernise infrastructure to:
• Become cloud-ready and API-enabled.
• Unify all sites and assets into one connected network.
• Enable predictive maintenance to reduce downtime.
• Upgrade to modern security and compliance standards.
Our proven methodology ensures your systems remain secure and compliant throughout the modernisation journey. We prioritise operational stability and data integrity at every stage.
Experience faster time-to-value with our agile, scalable approach. We help you adapt to evolving business needs and emerging technologies—future-proofing your IT landscape.
Iron Code Labs delivered a phased modernisation program, migrating the company’s legacy control rooms to a cloud-ready, web-based platform while ensuring zero disruption to daily operations. We unified all 28 sites, integrated equipment and vehicles through secure APIs, and introduced predictive maintenance capabilities to cut downtime and reduce operational costs.
• 28 sites fully connected into a single, secure operational network.
• Predictive maintenance enabled, reducing downtime and repair costs.
• Cloud-ready control rooms delivering scalability, compliance, and long-term resilience.
The Solution
IronCodeLabs designed and delivered a phased modernisation program to minimise disruption while delivering rapid results:
• Cloud-Ready Control Rooms: Migrated legacy control systems to a modern, web-based platform built on scalable cloud architecture.
• Full-Site Connectivity: Connected all 28 sites into one unified, secure network - enabling real-time monitoring of operations across borders.
• IoT & API Enablement: Integrated vehicles, machinery, and plant equipment using APIs and industrial IoT frameworks.
• Predictive Maintenance: Deployed analytics and monitoring tools to track asset health, anticipate failures, and reduce downtime.
• Security & Compliance: Implemented robust, web-based security systems aligned with EU standards for industrial operations.
Continuous improvement is at the core of our process. We monitor, optimise, and adapt your systems to keep pace with industry changes and organisational growth.
This modernisation program transformed the recycling company’s ability to scale, optimise, and innovate. With connected control rooms, cloud readiness, and predictive maintenance, the company is now positioned to lead in efficiency and sustainability for decades to come - continuing the growth journey that began in 1955.
• 28 sites unified into a single, connected network.
• 100% visibility of equipment, vehicles, and plant performance in real time.
• Predictive maintenance capability deployed, cutting unplanned downtime and lowering repair costs.
• Seamless migration from legacy control tech to a modern, web-based API ecosystem without disrupting day-to-day operations.
• Improved security posture and compliance readiness across all European sites.