Unplanned downtime remains one of the costliest challenges in thermoforming operations. For plant managers, the root cause is often not mechanical failure—but outdated control systems that can no longer be supported when problems occur.

The Risk of Outdated Machine Controls

Legacy thermoforming controls may continue to run, but they introduce significant operational risk. As components become obsolete, sourcing replacements become increasingly difficult, and technical support is often unavailable.

When failure occurs, recovery timelines can extend far beyond typical maintenance expectations. Instead of hours or days, plants can face weeks—or even months—of lost production due to long lead times and limited replacement options. 

Downtime Cost in Thermoforming Operations

To understand the impact, let’s consider a conservative production scenario for a single thermoforming line consisting of a thermoformer and trim press. We have calculated the ROI with the machines running three 8-hour shifts five days a week with the cost of production being $2,000 per hour. These machines are receiving a full upgrade from their current control systems to BMG’s NextGen Controls package. 

BMG Controls Upgrade ROI

It is important to note this loss reflects lost output alone. Additional impacts—such as missed deliveries, labor inefficiencies, and customer risk—can significantly increase total cost.

Controls Upgrade Cost vs ROI

A full controls upgrade for a thermoformer and trim press can cost up to $400,000. Although this is a significant capital investment, it should be weighed against the cost of extended downtime. A proactive controls upgrade can help your company avoid up to $4.4 million in potential unplanned downtime per thermoforming line.

From a ROI perspective:

• Avoiding one major failure can recover a large portion of the upgrade cost
• The upgrade can be planned based on your production schedule minimizing downtime
• Modern controls reduce the likelihood of repeat downtime events
• Improved system reliability supports consistent production output

For plant managers, this shifts the decision from reactive maintenance to proactive risk management.

Improving Uptime with Modern Controls

New controls systems are designed for the next generation of machine operators. Easy to learn and use regardless of operator experience. Upgrading control systems provides measurable operational benefits:

• New intuitive screens with online help, machine manuals, bills of materials and drawings
• 2-Click/tap access to any screen
• Tool overlay on oven screens to assist with accurate heat profiles
• Faster troubleshooting and diagnostics
• Improved parts availability and support
• More predictable production scheduling
• Complete support by BMG

Proactive modernization allows plants to control upgrade timing, rather than reacting to unexpected failures that disrupt operations.

At BMG, we partner with plant teams to assess control system risk, plan upgrades strategically, and implement solutions that improve uptime and long-term performance. If you need assistance gaining approval from management, we will assist you with every step. Our success is measured by your success. 

Let’s talk.