Why OEMs partner with Gross Automation for Danfoss programs

Every engagement combines rigor in requirements capture, Danfoss-certified panelization, and remote lifecycle governance. Use these proof points to brief executive sponsors or technical stakeholders.

Modernization velocity

Retrofit playbooks shrink downtime windows

Prefabricated UL508A/UL698A panels, pre-validated PLC templates, and drive parameter packs allow us to swap legacy controls in hours, not days.

  • Digital twins mirror production to validate changeover
  • Command center schedules phased cutovers by shift
  • Documented rollback plans satisfy OEM risk teams
Lifecycle assurance

Command center coverage keeps fleets producing

24/7 diagnostics, DrivePro® analytics, and spare strategies reduce support dispatches while giving OEM leaders real-time dashboards.

  • Average alarm closure under 42 minutes
  • Remote firmware governance and backups
  • Monthly health reviews with KPI scorecards
Co-engineering confidence

Field-tested PLC adaptations for industrial duty

We industrialize the Danfoss HVAC PLC with hardened IO, safety libraries, and cybersecurity controls that align with IEC 62443 expectations.

  • Temperature and vibration stress testing
  • Safety-rated function blocks with documentation
  • EtherCAT, Profinet, and Modbus connectivity packs

Filter case studies by industry, outcome, or lifecycle stage

Use the filters to focus on examples most relevant to your OEM program. Each card links to deeper commissioning notes and stakeholder-ready summaries.

Industry
Primary outcome
Lifecycle stage
Material handling modernization

Robotics integrator lifts uptime by 23%

Gross Automation replaced legacy drives with VLT® AutomationDrive FC 302 units, deployed Danfoss PLC safety libraries, and staged cutovers with remote oversight.

Result
23% uptime increase
Scope
62 FC 302 drives, 9 PLC racks
Timeline
14 weeks, phased
  • Digital twin validated conveyor sequencing before install
  • Command center closed alarms without site dispatch
  • Safety functions STO, SS1, SLS certified across robots
VLT® AutomationDrive Danfoss PLC Modernization
See detailed execution Plan a retrofit review
Water & wastewater

Utility cuts pumping energy by 47%

Coordinated VLT® AQUA drives with Danfoss PLC telemetry smooths pressure zones, trims peaks, and provides compliance reporting.

Result
$185k annual savings
Scope
12 pump trains, 18 PLC nodes
Timeline
8 month rollout
  • IEEE 519 compliance achieved without AFE swaps
  • DrivePro® analytics predict filter maintenance
  • Remote dashboards feed executive board updates
VLT® AQUA Telemetry Energy savings
Explore telemetry stack Request energy model
Healthcare campus

Hospital maintains uptime during retrofit

Adapted Danfoss HVAC PLCs and redundant VLT® FC 102 drives ensured continuous surgical suite operations while controls were modernized.

Result
0 hours downtime
Scope
1.2M sq ft campus
Timeline
10 month migration
  • Redundant PLC CPU and network architecture
  • Gross Automation staff onsite & remote command center
  • Joint risk reviews satisfied compliance committees
VLT® HVAC Danfoss PLC Critical infrastructure
View mitigation plan Schedule readiness audit
Energy storage launch

Battery OEM accelerates production ramp

VACON® drives, prefab panels, and PLC templates kept a new manufacturing line ahead of investor milestones with remote commissioning support.

Result
40% faster commissioning
Scope
24 VACON® panels/month
Lifecycle
DrivePro® tiered support
  • Factory acceptance tested via remote witness streaming
  • Command center resolved 92% of tickets without travel
  • Joint engineering sprints shortened UL approvals
VACON® Industrial Prefab panels Launch velocity
See prefab workflow Book a launch workshop

Deep dives for engineering and executive audiences

Share these briefs with your team to understand scope, KPIs, and Gross Automation’s delivery methods before launching discovery sessions.

Material handling modernization

Palletizing retrofit execution highlights

Deliverables
UL508A panel builds, PLC safety library, digital twin testing, onsite and remote commissioning
Stakeholders
OEM controls lead, plant operations manager, Gross Automation command center
KPIs
23% uptime increase, 35% faster MTTR, 12% energy reduction
“Gross Automation’s Danfoss team gave us a phased retrofit plan that let us upgrade conveyors between shifts without disrupting production.” — VP of Operations, Robotics Integrator
  • PLC templates synchronized robotics, conveyors, and safety zones
  • Command center monitored cutovers with live telemetry dashboards
  • After-action reviews produced a modernization playbook for additional sites
Water & wastewater modernization

Coordinated pump control and telemetry

Deliverables
Drive parameter commissioning, PLC telemetry scripts, harmonic mitigation, operator training
Stakeholders
Utility engineering director, finance, Gross Automation energy analytics team
KPIs
47% energy reduction, $185k annual savings, pressure variance under 2 psi
“The remote dashboards and DrivePro insights justify ongoing investment; we can prove savings every billing cycle.” — Director of Engineering, Municipal Utility
  • Adaptive pump staging keeps demand charges below target bands
  • Remote diagnostics handled 88% of after-hours calls
  • IEEE 519 compliance validated by Gross Automation power quality team
Healthcare retrofit

Critical HVAC controls transformation

Deliverables
Redundant PLC architecture, VLT HVAC commissioning, cybersecurity hardening, compliance documentation
Stakeholders
Hospital facilities leadership, infection control, Gross Automation compliance specialists
KPIs
0 downtime events, commissioning reduced by 30%, 100% remote alarm coverage
“Weekly readiness reviews with Gross Automation kept our executive steering team confident that patient areas remained protected.” — Executive Director of Facilities, Regional Hospital
  • IEC 62443-aligned policies, role-based access, and secure remote gateways
  • Hot-swap PLC capability allowed changeovers during live operations
  • Commissioning documentation satisfied state healthcare regulators
Energy storage launch

Prefab Danfoss panels accelerate production

Deliverables
VACON panel fabrication, PLC template creation, remote FAT/SAT, DrivePro® lifecycle services
Stakeholders
OEM program management, investor oversight, Gross Automation fabrication & command center teams
KPIs
40% faster commissioning, 92% remote ticket closure, 100% UL compliance on first audit
“The prefab Danfoss panels and remote commissioning model gave us the speed investors demanded without sacrificing reliability.” — VP of Engineering, Energy Storage OEM
  • Panel travelers logged torque, firmware, and quality data for each build
  • Gross Automation command center provided 24/7 launch floor support
  • Lifecycle plan aligned DrivePro® services with fleet expansion schedule
Ready to build your success story?

Engage Gross Automation’s Danfoss experts for a scoped pilot

Share your performance targets and constraints. We will prepare a Danfoss-aligned execution plan with timelines, panel concepts, and lifecycle support modeled on the case studies above.

Start a project conversation Download proof packs