Retrofit as an economic and sustainable lever in dynamic times
Retrofit - Machine Overhaul
Secure your competitiveness and productivity through targeted retrofit by economically modernizing your existing production facilities.
What does retrofit mean?
Retrofit refers to the modernization and upgrading of existing machines and systems to bring them up to date technically, mechanically, or digitally. It offers a cost-effective and resource-saving alternative to purchasing new equipment, as proven basic structures are preserved and reused.
An overview of the most important application areas and advantages:
Digital Retrofit (Industry 4.0): Older machines are equipped with sensors and communication technology to record machine status and process data and, for example, minimize downtime.
Energy and Resource Efficiency: Replacing outdated motors, drives, or control systems makes it possible to reduce energy consumption to the level of modern new systems and reduce CO2 emissions.
Economic Efficiency: The conversion avoids the high costs and long delivery times of a new purchase. In most cases, extensive retraining for personnel is also unnecessary, as the core operation of the system remains the same.
Optimize your production facilities, for example, through
- mechanical optimization of cycle and clamping systems
- retrofitting of automation modules in assembly or handling processes
- integration of modern safety and sensor systems
- replacement of outdated control systems
with the goal of
- planned step-by-step modernization without major investment
- extension of the service life of existing facilities
- relief during personnel shortages
- higher process stability and quality
- achieving shorter cycle times
- reduction of downtime and maintenance costs
- investing significantly below new equipment prices
- faster return on investment
Retrofit examples in before / after pictures
Machine before / after retrofit
Control cabinet before / after retrofit
Utilize our modular implementation steps
- Analysis to determine automation potential: Machine condition, bottlenecks, wear points
- Concept development: Mechanics, control, drive, sensors, safety and protective equipment according to the Machinery Directive
- Simulation and validation: 3D design, cycle time and load simulation
- Implementation and integration: Retrofit modules, commissioning, training, employees
- Monitoring and optimization: Process monitoring
Pneumatics before / after retrofit
Result: Your economic benefit – practical values
- Cycle time optimization: +10 to 25% more output
- Reduced downtime: -20-40% unplanned failures
- Automation of manual activities: savings of 0.5 to 2 employees per line
- Energy optimization: -5-15% consumption
- Maintenance costs: significant reduction through modern components
- Investment volume: typically 30-60% below a new facility
- ROI: frequently 12 to 36 months
Examples:
Modernization - Retro-Fitting - General Overhauls
Wartung eines Mehrspindelkopfes
Reparatur einer Kugelrollspindel
Zylinder_neu
Pneumatik-Insel_Neu
neuer_Servomotor
neue_Visualisierung
neue_Pneumatik
neu_Abtastvorrichtung
Nadelbeschrifter-neu
Eingangsmodule_neu
Demontage
alte_Verschlauchung
nach_Retrofit
