The Upgrade for Production: Where Retrofit Is Headed

Integrating new technologies into existing equipment is often more complex than it first appears. A key factor for success is whether suitable replacements for existing components can be found and how easily they can be integrated into the current system.

“New components and software are not always compatible with older system platforms,” says Daniela Verhaeg, Communications Manager at Mettler Toledo. As a result, companies must carefully assess whether the required spare parts are still available, which current requirements, for example those imposed by retailers, need to be met, and whether the desired data management or software solutions can be implemented on the existing system.

“Economic viability is also a key consideration,” Verhaeg explains. “As equipment ages, maintenance requirements, spare parts demand, service interventions and unplanned downtime can increase. That is why every retrofit project must be evaluated to determine whether modernization remains economically viable over the system’s remaining service life, or whether replacement would be the better long-term solution. An additional challenge is that future failures and the associated costs cannot be predicted reliably.”

Another challenge is carrying out retrofit projects on active production lines. “Retrofitting equipment while it remains in operation can be particularly demanding, as only very short downtime windows are often available,” says Hans-Joachim Müller, Marktmanager Antriebselektronik at SEW-EURODRIVE. “Precise planning and close coordination among all parties involved are therefore essential to ensure continued equipment availability.”

The shortage of skilled labor, ease of operation and automation are additional drivers behind retrofit projects. Modern production systems are expected to be as user-friendly as possible while reducing the need for manual intervention.

“Modernization can introduce remote diagnostic capabilities, for example, enabling fault analysis and some service activities to be carried out remotely,” says Müller of SEW-EURODRIVE. New drive technologies also offer extensive diagnostic and service functions, simplify commissioning and support advanced safety and communication standards. At the same time, they help ensure the long-term availability of spare parts and technical support.

Mettler Toledo sees similar benefits. “Modern systems can reduce training requirements for operators because product settings and changeovers can be automated,” says Verhaeg. This simplifies operation while helping to minimize errors. Features such as the ability to quickly switch the user interface between different languages also make day-to-day production work easier.

In addition, data can be collected automatically and made centrally available through data management software. Once configured, modern or upgraded systems can automate many routine processes, reducing the need for manual intervention and further improving operational efficiency.

Every machine that remains in operation for longer helps conserve resources. Repairing or upgrading equipment instead of replacing it therefore makes a significant contribution to sustainability. This is one of the key advantages of retrofit.

“One of the main benefits is that it avoids the need for a new capital investment,” says Ayadi Taheri of Herrmann Ultrasonics, a specialist in ultrasonic welding technology.

Verhaeg agrees: “Instead of replacing an entire system that is still fundamentally functional, worn or technologically outdated components are selectively upgraded or replaced, extending the service life of existing equipment. This allows companies to continue using their installed asset base for many more years and maximize the value of their original investment.”

She adds: “Replacing a complete machine requires significantly more resources than a targeted modernization. These include manufacturing the new machine, packaging and transportation, the labor required for replacement and installation, as well as the dismantling, recycling or disposal of the existing system. If a machine can continue to operate effectively through a retrofit, these additional efforts can be reduced or postponed.”

Müller highlights another sustainability benefit: “Modern motors and drive systems can also deliver significant energy savings. A typical example is replacing pneumatic drives with electric drive solutions. These are often much more energy-efficient while also providing improved control and diagnostic capabilities.”

All three experts agree that retrofit is far from reaching its full potential. In particular, the rapid development of software capabilities, cloud platforms and artificial intelligence is opening up entirely new possibilities.

“A prerequisite for this is the availability of high-quality operational and process data. Retrofit solutions create the foundation for collecting and analyzing this data, enabling innovations to be integrated into existing production environments much more quickly,” says Müller.

According to Müller, diagnostic, service and safety functions will continue to gain importance in the years ahead. Simplified commissioning, improved connectivity and long-term spare parts availability will make modernization projects even more attractive while helping to extend machine lifecycles sustainably.

Regulatory requirements could also further drive demand. “We expect market requirements to continue increasing overall. The Cyber Resilience Act may become an additional driver in this regard,” says Abdelmounaim Ayadi Taheri, Customer Success Engineer Packaging at Herrmann Ultrasonics. As a result, retrofit is likely to remain an important topic for industry in the years ahead.

At the same time, the way companies view existing equipment is changing. The age of a machine is no longer the decisive factor. What matters today is the development potential that can still be unlocked through new technologies. That is precisely why retrofit is expected to become an integral part of investment planning in many manufacturing operations in the future.