Retrofit and modernisation
Production line and machine retrofit.
The mechanics of your line will last for years yet, the controls will not. We replace obsolete PLCs, drives, sensors and visualisation, bring safety up to current standards and plan the conversion so production stops for as short a time as possible.
A new line is not the only option.
A production line retrofit makes sense when the machine is mechanically sound but the control system can no longer be bought, spare parts are hard to find and nobody in the plant understands the program. Instead of investing in a new line, we replace what ages fastest: the controls, drives, sensors, HMI and safety circuit. The result is a machine that behaves like new, without the cost and risk of an entirely new line.
We modernise individual machines, production units and entire lines. Typically this means migrating to a new PLC with the program rewritten, replacing drives with variable speed drives and servos, adding a sequence for a new product variant, extending a conveyor or modifying a machine imported from abroad so that it meets the requirements for CE marking. On retrofits of welding, handling and marking units we also supply mechanical components, such as welding heads and grippers.
The biggest risk in a retrofit is downtime. That is why we build the panel and test the program in advance, while the line is still producing, and carry out the conversion itself during a planned shutdown. We support the ramp-up right on the line until the machine runs at full cycle rate without nonconformities. Our engineering team has been carrying out work like this since 1993, in Slovakia and the Czech Republic. After handover you receive updated schematics, a program backup and a trained maintenance team that understands the new controls.
What we modernise in a retrofit.
Controls and PLC retrofit
Migration from obsolete control systems to current PLCs. We analyse and document the original logic and rewrite it clearly, with backups.
Drives and inverters
Replacing old drives with variable speed drives and servo drives. Smoother running, lower consumption and fault diagnostics right on the display.
Safety and CE
Risk assessment, light curtains, safety relays and PLCs, emergency stop. We bring the machine into line with the requirements for CE marking.
Sensors and detection
New position and presence sensors, automatic defect detection and vision inspection instead of visual checks by the operator.
HMI and new product variants
New visualisation with variant selection, recipes and diagnostics. Adding a production sequence for a new product type without rebuilding the whole line.
Connection to production data
The old machine starts sending its status, downtime and part counts to MES or a historian. Without that, OEE cannot be measured honestly.
What the retrofit includes.
We deliver the retrofit as a complete package, with design, manufacture and responsibility for the ramp-up.
- Machine audit and proposed scope of modernisation
- Risk assessment to EN ISO 12100 and safety functions to EN ISO 13849
- Electrical design and a new control panel with switchgear
- Mechanical modifications, grippers, fixtures and guards
- New PLC, robot and HMI program
- Installation during a planned shutdown, commissioning and ramp-up
- Removal of nonconformities and documents for conformity assessment and CE marking
- Updated documentation and maintenance training
Control systems and components we work with
How a retrofit works without a long shutdown.
Condition audit
We go through the mechanics, electrical installation, program and documentation. We tell you what is worth replacing and what to keep.
Preparation off the line
Design, panel build and the new program. We test the logic in simulation while the line is still producing.
Conversion during the shutdown
Removal, installation and wiring to a detailed schedule within the planned shutdown.
Ramp-up and handover
Commissioning, safety function tests, production support and new documentation with a program backup.
Related services.
PLC programming
PLC control systems, HMI operator panels and SCADA for Siemens, Rockwell, ABB, Omron and Schneider.
Electrical design and control panels
HV and LV electrical design, bespoke control panels, installation, commissioning, inspection and multilingual documentation.
Automation service
24/7 service for PLCs, drives, HMIs, robots and cameras. Contract service, remote access and valve actuator refurbishment.
Frequently asked questions.
Did not find your answer? Write to us and we will reply within 24 hours.
When is a retrofit worth it instead of a new line?
When the mechanics are in good condition and the product is not changing substantially. A retrofit of the controls, drives and safety usually costs a fraction of a new line, and the machine does not have to be developed from scratch. If the mechanics are worn or you need a significantly different cycle time, we will honestly recommend a new line.
How much does a production line retrofit cost?
It depends on the number of machines, the scope of replacement, the state of the documentation and whether the mechanics and safety also need changing. After the audit you receive a budget broken down by section, so you can also modernise in stages. We give a fixed price after the technical concept.
How long will the line be down during a retrofit?
We shorten the shutdown by preparing in advance. The panel is built and the program tested before we touch the line. The length of the conversion depends on the scope, and you receive the shutdown schedule in writing before work starts.
Does a machine need a new CE conformity assessment after a retrofit?
It depends on the scope of the changes. A substantial modification that changes the function or risks of the machine requires a new conformity assessment. We carry out the risk assessment, remove nonconformities and prepare the technical documents, including for machines imported from abroad.
Can you take over a machine with no documentation or source program?
Yes. We map the electrical installation, read the program out of the PLC if the system allows it, and document the machine's function directly on the line. We then hand over the new controls with complete documentation and a backup.
Do you also modernise machines from foreign manufacturers?
Yes, the original manufacturer's brand is no obstacle. When choosing the new controls, we take into account the systems you already have in the plant, so your maintenance team does not have to learn another platform.
Show us the machine you want to save.
Send us photos of the machine and the control panel, the control system type and what troubles you most. We will get back to you within 24 hours and arrange a site visit and a free consultation.