HOLISTIC MACHINE MODERNISATION
Discontinued control components, incomplete documentation and increasing failure risk leave many operators with the same question: how can the existing machine continue to operate reliably?
PRACTICAL EXAMPLES
A machine retrofit rarely affects just one component. The appropriate measures depend on the condition of the equipment, the available documentation and your objectives for continued operation. The following examples show typical areas of a holistic machine modernisation.
01
Migrate discontinued PLC and HMI systems to modern controls of leading manufacturers.
02
Replace servo drives, frequency converters, motors, valve terminals and other actuators with current, long-term available components
03
Refurbish or replace worn guides, spindles, bearings, drive elements and guards
04
Review outdated safety relays, guard-door switches and emergency-stop circuits and replace or supplement them with modern safety components
01 · INITIAL SITUATION
A machine retrofit is appropriate when outdated technology, changed safety requirements or missing digital connectivity increase the operational risk of an existing machine or production system.
01
INCREASED FAILURE RISK
Legacy controls, worn mechanics and unavailable hardware increase the risk of failure. Discontinued components make repairs and spare-parts supply more difficult.
02
MACHINE SAFETY
Changed requirements for occupational and machine safety and the current state of technology require a new project-specific assessment.
03
CONNECTIVITY & REMOTE SERVICE
Network connectivity enables remote diagnostics and service access and provides structured machine and production data for analysis and optimisation.
02 · TECHNICAL SCOPE
We combine controls, electrical engineering and automation with mechanical modifications and machine safety in one coordinated retrofit package.
01
Retrofit controls, HMI and electrical engineering, with migration to common platforms from leading manufacturers
02
Upgrade sensors, drive technology and mechanical components to current safety standards
03
Increase machine performance through tailored upgrades to mechanics and actuators
04
Add IoT connectivity for remote access, remote service and structured analysis of production data
03 · RECOMMISSIONING & SERVICE
The completed machine retrofit secures system availability, extends diagnostics and remote service, updates machine safety and provides complete digital documentation.
01
SYSTEM AVAILABILITY
Available components, secured software versions and documented spare-parts management stabilise operation and significantly reduce technical failure risks.
02
REMOTE SERVICE & DIAGNOSTICS
The connected machine enables fast service access, transparent fault diagnostics and structured analysis of process and machine data.
03
MACHINE SAFETY
The agreed safety upgrade is implemented in line with the current state of technology and documented for commissioning.
04
DIGITAL DOCUMENTATION
Circuit diagrams, software versions and project-relevant records are updated, eliminating searches through outdated paper files.
04 · IMPLEMENTATION
Four clearly defined phases provide a predictable conversion—from technical assessment to commissioning of the modernised machine.
ASSESSMENT
On site, we assess condition, fault history, documentation, spare parts, interfaces and possible conversion windows.
PREPARATION
We secure the existing system, define conversion packages and plan downtime, materials, software and fallback options.
CONVERSION
We modernise the machine in our assembly hall or carry out the conversion directly at your site.
COMMISSIONING
We test the agreed functions, restart the modernised machine in a controlled manner and hand over software, backups and documentation.
DISCUSS YOUR PROJECT WITH US
Photos, available documentation and a brief description of current issues allow us to prepare an appropriate system assessment.