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Line Retrofit & Modernisation

We retrofit legacy control systems, upgrade machinery to meet current Machinery Directive compliance, and integrate them into existing infrastructure.
Retain the mechanics. Modernise the controls.
Is your mechanical hardware still sound?
Upgrade to modern control systems before legacy failures cause unexpected downtime.
When migrating from legacy control architectures to modern platforms, we reprogram logic functions and adapt electrical circuits to match current production demands—ensuring strict compliance with European safety standards and machinery directives. Where mechanical assemblies remain fully serviceable, retrofitting the control layer extends machine service life at a fraction of the cost of building from scratch.
  • Control system upgrades including rewritten PLC logic and redesigned HMI visualisation
  • Compliance with the latest Machinery Directive and industrial safety regulations
  • Seamless integration with existing infrastructure and higher-level MES/ERP platforms
Footprint optimisation, energy efficiency, and operational data visibility

Upgrading the control system reduces cabinet footprints and cuts overall energy consumption across power and drive systems. Operators and maintenance teams gain immediate operational transparency and actionable diagnostics, allowing direct connectivity into plant-wide SCADA and factory monitoring networks.

  • Control system migration — High-performance PLC hardware, re-engineered control architecture, and modern HMI visualisation. Resulting in lower operator vulnerability and dependable cycle stability.
  • Safety and compliance — Integrated safety system redesign, strict alignment with the Machinery Directive, and complete technical documentation. Minimises human presence in hazardous operating zones.
  • Optimisation and throughput — Line cycle optimisation and overall productivity gains paired with superior workstation ergonomics. Ensures predictable operation and eliminates control-related breakdowns.
Case Study: Automotive assembly line retrofit

We delivered an extensive retrofit of an automated assembly and soldering line for a Tier-1 automotive component manufacturer. Scope included redesigning functional safety circuits, overall line optimisation, electrical rewiring, new PLC architecture with tailored HMI visualisation, machine compliance for Total Productive Maintenance (TPM), and on-site commissioning with personnel training.

"We completed the retrofit entirely within our scheduled maintenance shutdown window. The original mechanical base was preserved, but the line now delivers monitoring and diagnostic performance on par with a brand-new asset."

Maintenance Department
Automotive Component Supplier

The line was aligned fully with Machinery Directive standards. The soldering cell was entirely re-engineered with automated part feeding, eliminating manual intervention in dangerous zones. Redesigned manual assembly stations maintained nominal output while improving operator ergonomics, supported by an integrated Andon system for clear machine state visualisation. Control optimisation delivered stable cycle performance and significantly reduced troubleshooting times for plant maintenance.

Request a Retrofit Assessment

Do you run machines with sound mechanics but failing control hardware?
Describe your setup and machine architecture—we will respond with a preliminary retrofit scope and estimated project schedule.

Inquire

We provide a comprehensive engineering approach.

The pathway to full automation: from initial needs analysis to ongoing lifecycle support.

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01 Audit and Concept

We analyse the process from the ground up: requirements, production environment, and technical and organisational feasibility. The deliverable is a defined concept and project scope – an engineering baseline for discussion, not a rigid template.
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02 Design and Simulation

Mechanical, electrical, and pneumatic design, PLC programming, and HMI visualisation. We simulate the process alongside your team to eliminate design and functional discrepancies prior to machine build.
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03 Build and Acceptance Testing (FAT/SAT)

We build the machine and test it in-house prior to dispatch. The system arrives at your plant pre-validated, eliminating the need to commission from scratch in an active production environment.
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04 Commissioning and Continuity Maintenance

We commission on-site, train operators and maintenance teams, and hand over complete technical documentation alongside the CE declaration of conformity. Following production start-up, we provide ongoing operational support.
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Frequently Asked Questions

What to consider before launching the project
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More questions? Contact our engineering team to discuss technical feasibility.

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Will throughput increase or decrease following the retrofit?

It depends on the modernisation scope. Where compliance with the Machinery Directive requires introducing safety interlocks or light curtains, specific manual cycles may require minor deceleration for operator safety. Conversely, retrofits incorporating automated sub-modules accelerate takt times and alleviate operator workload. The exact performance goals are defined during the initial audit.

How long will production be stopped during the retrofit?

Depending on work scope—historically ranging from one to three weeks. We engineer and pre-commission off-site to execute installation strictly within your planned maintenance shutdown window.

Is a retrofit always economically viable?

Not in every case. If kinematic and mechanical components are intact, replacing the control platform costs significantly less than buying new capital equipment. However, when an asset is severely degraded and demands widespread component overhauls, we transparently advise investing in a new custom machine—backed by complete warranties and domestic engineering support.

Will integrating a new machine disrupt my main production line?

We pre-assemble and validate modules so mechanical and electrical drop-in takes minimal time. Keeping line downtime to an absolute minimum directly protects your operational margins.

Do you retrofit third-party machinery?

Yes. We work on third-party installations, adapting legacy control programs, drive hardware, and electrical distribution to meet modern technical and safety requirements.

Will the machine comply with the current Machinery Directive after modernization?

Yes. Ensuring compliance with the Machinery Directive and delivering updated mechanical and electrical schematics is an integral part of the retrofit scope.