Retrofit Instead of Replacement: Giving Machines a Second Life

“Especially in the current economic climate, investments in modernization, upgrades and retrofits are often easier to justify than the purchase of completely new systems, provided that a clear benefit can be demonstrated, such as ensuring machine availability,” says Hans-Joachim Müller of SEW-EURODRIVE. For the company, which specializes in drive and automation technology, retrofit has become much more than a traditional service business. As a strategic field of activity, it helps customers safeguard and enhance the long-term performance of their production assets. Müller explains: “Our projects range from short-term measures following an unexpected equipment failure, where rapid response is critical, to carefully planned modernization projects covering entire production lines or manufacturing plants.”

Modernization instead of replacement also plays an important role at Mettler Toledo. “Our goal is to keep product inspection systems performing effectively for as long as possible and to enable our customers to maximize the return on their original investment,” says Daniela Verhaeg, Communications Manager at Mettler Toledo. “Through upgrades, we can keep older systems up to date both functionally and technologically, while extending their service life.”

The examples show that retrofit has long evolved beyond a purely technical option. For many companies, modernizing existing equipment has become a strategic response to economic and operational challenges. Investment budgets remain under pressure, while production systems must continue to perform reliably. As a result, many manufacturers are looking for ways to adapt existing technology to new requirements.

“We have been seeing this trend for many years,” says Abdelmounaim Ayadi Taheri, Customer Success Engineer Packaging at Herrmann Ultrasonics. According to Taheri, the COVID-19 pandemic, the war in Ukraine and the economic downturn have brought retrofit even more strongly into focus for machine operators and manufacturers alike.

A key reason, according to Müller of SEW-EURODRIVE, is product discontinuation, when spare parts or existing components are no longer available. “In addition, many customers choose retrofit solutions to expand existing systems or adapt them to new production requirements. Regulatory demands, for example in the areas of safety, energy efficiency or compliance with standards, can also make modernization necessary or at least advisable,” he explains. “Last but not least, retrofitting provides an opportunity to implement technical improvements and enhance the performance of existing machinery without having to invest in a completely new system.”

Verhaeg of Mettler Toledo, a specialist in precision weighing and inspection solutions, sees particularly strong demand in highly regulated industries such as pharmaceuticals. “If an existing system is already part of validated processes and established standard operating procedures (SOPs), it may make sense for customers to retain the proven platform and selectively modernize individual components,” she says. Examples include software upgrades or the replacement of reject and sorting devices, which improve product handling while remaining compatible with the existing system.

“Software is a particularly important consideration,” Verhaeg adds. “If an IT environment depends on specific system configurations or still relies on legacy systems, especially where validated protocols are involved, customers may not be ready to replace their equipment entirely.”

In many cases, software is a key area that companies want, or need, to keep up to date. “Digitalization is an important element of modern retrofit concepts. Through electronics and software upgrades, existing systems can be enhanced with modern connectivity and data acquisition capabilities,” explains Verhaeg.

Many older systems that have been in operation for ten years or more still rely on USB connections, hard-wired links or other physical interfaces. “If these systems can be upgraded with Wi-Fi connectivity, for example, performance data can be monitored more easily and the systems can be integrated more flexibly into the existing production environment,” she says. This is particularly beneficial when physical connections are limited or when equipment needs to be relocated within a production facility, as extensive rewiring can be avoided.

Such upgrades also enable larger volumes of data to be collected and processed, creating the foundation for condition monitoring and predictive maintenance applications.

At SEW-EURODRIVE, the components most commonly replaced are drive-related technologies such as motors, frequency inverters and drive electronics. “In many cases, however, a more comprehensive approach is advisable, including upgrades to the control technology and operator interfaces,” Müller explains.

Another advantage is simplified commissioning and diagnostics. Even greater opportunities arise through the use of intelligent drive technology, additional sensors and cloud connectivity. Modern remote service concepts also provide rapid access to diagnostic data, helping to improve maintenance efficiency and accelerate troubleshooting.