ENGINEERING · MACHINE RETROFIT
We modernise existing machines and production systems in a targeted manner, covering controls, HMI, drive technology, electrics and machine safety. The scope is based on the system condition, documentation and planned production target.
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?
EXAMPLES FROM PRACTICE
NIKLAS Engineering & Service modernises existing machines, automated cells and linked production lines. Our machine retrofit work covers equipment groups such as:
Manufacturing and processing equipment: Machines for producing, forming, machining and processing components or materials.
Assembly and automation systems: Assembly stations, robot cells and systems for feeding, joining or positioning.
Conveying, handling and packaging equipment: Systems for material transport, sorting, product handling and packaging.
Test, process and special-purpose systems: Test benches and custom-built machines for defined processes and specific production tasks.
The equipment types listed here are drawn from projects we have completed. We also welcome enquiries about other machines and systems.
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A machine retrofit is appropriate when outdated technology, changed safety requirements or missing digital connectivity increase the operational risk of an existing machine or production system.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.
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
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.
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.