Why replace costly pushbutton panels with Maple Systems HMIs

Pushbutton panels are simple and reliable, but their functionality is limited as systems grow more complex. They depend heavily on operator skill, offer no real-time data visibility, and require costly hardware maintenance.

Plants have been running for years using pushbutton equipment control. This method is well understood by the people who operate these systems and their efficiency is directly tied to the experience, proficiency and focus of the operator. However, an HMI can streamline manufacturing processes by centralizing all functions of each button into one location.

Maple Systems HMIs can perform all the same tasks as mechanical switches, LEDs, and indicators without physical wear. Each button or lamp appears virtually on the LCD touchscreen, offering clear visualization, easier troubleshooting, and faster operator response.

Benefits of switching to an HMI Interface

Replacing mechanical pushbuttons with an HMI interface brings far more than aesthetic or space-saving improvements. It fundamentally changes how operators and machines interact. An HMI consolidates all control functions into one intuitive touchscreen display, simplifying system operation and improving situational awareness on the plant floor.

Centralized control and visualization

Instead of scattered pushbuttons and indicator lights, HMIs deliver a unified view of system performance. Operators can monitor live process data, view alarms, and make adjustments instantly, reducing reaction time and human error. A single Maple Systems HMI can display multiple screens, each tailored to specific processes or user levels.

Reduced maintenance and downtime

Mechanical switches and lamps wear out, especially in demanding environments. By replacing them with digital controls, you eliminate physical failure points. Fewer moving parts mean less maintenance, reduced spare-part inventory, and fewer production interruptions.

Enhanced data collection and traceability

Modern HMIs record process data, alarm histories, and user actions. All of these provide valuable insights for troubleshooting and continuous improvement. This data can be exported or shared across connected devices, supporting IIoT initiatives and predictive maintenance strategies.

Flexible communication and integration

Maple Systems HMIs support a wide range of industrial protocols, allowing seamless communication with PLCs, drives, sensors, and other controllers. This connectivity enables cross-system coordination and simplifies integration in both legacy and new installations.

Improved safety and user access control

Built-in user authentication ensures only authorized personnel can perform critical actions. Customizable access levels and secure logins prevent unauthorized changes and improve accountability across teams.

In short, HMIs transform static, hardware-based control systems into dynamic, data-driven interfaces that improve efficiency, reliability, and safety.

Factors to consider when replacing a pushbutton panel

As factory processes and control systems grow more complex, it is apparent that having a graphical display on control panels becomes the best solution in almost all cases. Also, systems that need to communicate with each other, require a display in order to run efficiently. In most cases, an entire system with multiple pieces of equipment can be run from one well integrated HMI display.

While we do recommend retrofitting an older pushbutton panel to an HMI display in order to gain the advantages of an HMI, there are many things to consider:

• Project complexity – Maple Systems offers Conversion and Application Engineering support.
• Software cost – Our HMI software is completely free.
• Technical support – Customers receive free online and live support.
• Warranty – Most HMIs come with a 2-year warranty.
• User experience – Access training videos and webinars.
• Environment – All Basic HMI models are IP65/NEMA 4, CE, and RoHS certified, ideal for harsh industrial settings.

Replacing pushbutton panels with Maple Systems HMIs can reduce manufacturing costs, simplify system management, and increase profit margins. Our HMIs handle complex applications with multiple screens and parallel routines.