Legacy Upgrades & Retrofits
Modernising an existing production line requires careful planning, detailed engineering and a clear understanding of how to minimise production downtime. Our retrofit projects focus on extending machine life, improving reliability and introducing modern automation without replacing equipment that continues to perform its intended function.
Control Hardware Modernisation
Modernisation often begins with the control system. We replace outdated electrical hardware with reliable, maintainable solutions designed around current industry standards while retaining mechanical equipment wherever practical.
Typical hardware upgrades include:
- Modern control panels
- PLC and HMI replacement
- Variable Speed Drives (VSDs)
- Safety systems and Safety PLCs
- Protection devices and field I/O
- Industrial communication networks
The result is a cleaner, more reliable control system with improved serviceability and long-term component availability.
Control Software Modernisation
Modern hardware deserves modern software. Rather than simply transferring existing programs, we redesign the control software around the current production process while maintaining the original machine functionality.
Software improvements typically include:
- New PLC software architecture
- Modern HMI applications
- Improved diagnostics and alarm handling
- Structured, fully commented code
- Complete system backups
- Updated electrical documentation
The upgraded system is easier to maintain, troubleshoot and expand as production requirements evolve.
Planned Installation & Production Changeover
Successful retrofit projects are built around preparation. Most engineering work is completed before production stops, allowing installation to be carried out during the shortest practical shutdown window.
Our implementation process includes:
- Site survey and system assessment
- Backup of existing systems where available
- Offline software development
- Documentation and panel preparation
- Installation during planned shutdown
- Commissioning, testing and validation
This structured approach reduces production downtime while ensuring a controlled transition to the upgraded automation system.
