In a GxP environment with bespoke packing equipment you are spending anywhere from 1-4000 collective labour hours and anywhere from 50k-250k for a control system upgrade, URS/TRS/SDS, and Qualification. To give you an idea, on a therapeutic manufacturing plant you’re looking at a handful of two inch binders for the end to end system.

You are also (and more importantly) taking your resources off BAU or revenue generating improvement work for this project. You have a validated and qualified system, and even if you are spending $10-20k for a $500 like for like IPC or control card, the cost benefits of another 5 years is worth it.