Retrofit as a cost-effective and sustainable lever in challenging times
Retrofit in Mechanical Engineering
Safeguard your competitiveness and productivity with targeted retrofitting by modernising your existing production systems in a cost-effective, focused way.
What does retrofit mean?
Retrofit refers to the modernisation and upgrading of existing machines and systems to bring them up to date technically, mechanically, or digitally. It offers a cost-effective, resource-efficient alternative to purchasing new equipment, as proven core structures are retained and reused.
The key application areas and benefits at a glance:
Digital retrofit (Industry 4.0): Older machines are equipped with sensors and communication technology to capture machine conditions and process data and, for example, minimise 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Energy and resource efficiency: Replacing outdated motors, drives, or control systems makes it possible to reduce energy consumption to the level of modern new equipment and cut CO2 emissions.
Cost-effectiveness: Retrofitting avoids the high costs and long lead times of purchasing new equipment. In most cases, extensive retraining is also unnecessary, as the system’s core operation remains unchanged.
AUMAT Maschinenbau GmbH offers you comprehensive retrofit solutions
In principle, we can repair, service, and expand all machines that fall under mechanical engineering in the traditional sense. This includes the repair and maintenance of steel and aluminium parts, ball bearings, linear guides, as well as components that are still available on the market. In addition, we offer the integration of purchased parts, cylinders, actuators, and hydraulic components.
For components that are no longer available, we offer redesign and re-engineering.
We offer comprehensive retrofitting in the areas of feeding technology, handling, parts handling, and the rework of mechanical components.
In the handling area, especially parts handling where pneumatics, electric axes, and servo motors are frequently used, we can offer retrofitting in most cases. This also includes, for example, milling spindles, drilling fixtures, and conveyor technology.
AUMAT Maschinenbau carries out a comprehensive overhaul of the mechanical components, including manufacturing and assembly, as well as a complete redesign of the circuit diagrams through to control cabinet construction. In addition, we replace the old PLC with a new one or, if required, the entire control technology in cooperation with a partner specialised in this field.
Retrofit & modernisation not only for North Rhine-Westphalia
Our location in Solingen, in the Bergisches Land region, including the Ruhr area, Düsseldorf, Cologne, and the Lower Rhine, enables rapid implementation of retrofit projects for companies throughout North Rhine-Westphalia thanks to its strategic location. In addition, we support customers throughout Germany and in neighbouring EU countries.
The benefits of retrofit in mechanical engineering at a glance
Relieve your production systems, for example, through
- mechanical optimisation of indexing and clamping systems
- retrofitting automation modules in assembly or handling processes
- integration of modern safety and sensor systems
- replacement of outdated control systems
with the aim of
- planned step-by-step modernisation without major investment
- extending the service life of existing systems
- relief in times of staff shortages
- greater process stability and quality
- achieving shorter throughput times
- reducing downtime and maintenance costs
- investment significantly below the cost of new equipment
- faster return on investment
Retrofit examples in pictures: before / after
Machine before / after retrofit
Control cabinet before / after retrofit
Take advantage of our modular implementation steps
- Analysis to determine automation potential: machine condition, bottlenecks, wear points
- Concept development: mechanics, control system, drive, sensors, safety and protective devices in accordance with the Machinery Directive
- Simulation and validation: 3D design, cycle time and load simulation
- Implementation and integration retrofit modules, commissioning, training, employees
- Monitoring and optimisation process monitoring
Pneumatics before / after retrofit
Result: Your economic benefit – practical figures
- Cycle time optimisation: +10 to 25% higher output
- Reduced downtime: -20 to 40% unplanned failures
- Automation of manual tasks: savings of 0.5 to 2 FTE per line
- Energy optimisation: -5 to 15% consumption
- Maintenance costs: significant reduction through modern components
- Investment volume: usually 30 to 60% below a new system
- ROI: often 12 to 36 months
Examples:
Modernisation – 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
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Demontage
alte_Verschlauchung
nach_Retrofit
