Retrofit and modernisation
Machine retrofit and modernisation for existing machines
We modernise the controls, drives, operation and safety technology of your existing machine, in our assembly hall in Wörth an der Donau or at your site. We also migrate S5, S7-300 and S7-400 to current Siemens and Beckhoff controllers.
Modernisation of existing machines
The controller has been discontinued, circuit diagrams are incomplete, the machine fails more often: then it is worth looking at a retrofit.
We check at the machine what needs to be renewed and what can stay.
Go to the Retrofit CheckNIKLAS machine retrofit
By clicking “Show video” you allow YouTube to load this video and receive data such as your IP address. You can withdraw this consent in the cookie settings.
Selected customers
Is a retrofit worthwhile for your machine?
For the free Retrofit Check, we come to you and look at the machine. Afterwards we tell you whether a retrofit is worthwhile and which assemblies it affects.
- On site
Checking condition and documentation
We look at the condition, faults and available documentation. You show us what your system is to achieve in future.
- Options
What stays, what is renewed
We go through the controls, drives and electrical engineering with you and tell you which components can stay and which should be replaced.
- Next step
Initial assessment and next step
You receive an initial technical assessment and a concrete next step. We agree the safety assessment and detailed planning separately afterwards.
Machines for which we offer a retrofit
In many existing machines, the mechanics are in good condition. With new controls, new drives and up-to-date safety technology, they remain in service. We modernise individual machines, automated cells and linked production lines.
Machines for manufacturing, forming, machining and processing parts or materials.
Assembly stations, robot cells and systems for feeding, joining or positioning.
Systems for material transport, sorting, product guidance and packaging.
Systems for storage, order picking and in-plant material flow.
Test benches and custom-built machines for defined processes and particular production tasks.
This list comes from completed projects. Your machine belongs to a different group? Feel free to send us an enquiry.
Migrating controls to current platforms
We migrate your controls to Siemens S7-1200 or S7-1500 with ET 200SP distributed I/O in the TIA Portal or to all current Beckhoff controllers with TwinCAT 3. We plan the changeover around your downtime window.
Siemens S5
We back up the program and symbols, transfer the program to the TIA Portal with the Siemens converter and rebuild special blocks in SCL.
Siemens S7-300 and S7-400
We migrate your projects with symbols and comments in the TIA Portal and reuse existing I/O where it fits.
Other controllers
In the Retrofit Check we clarify condition, program version and target platform, even if documentation is missing.
We decide with you which platform fits, based on machine size, peripherals and the know-how of your maintenance team. Find out more in the Knowledge article PLC migration to S7-1500.
Arrange a free on-site check
We look at your machine on site and tell you which modules are worthwhile for a retrofit.
Drives, operation, safety and CE
Besides the controls, we renew whatever is outdated on your machine. After the Retrofit Check, we decide together with you which modules are needed.
Drives
We replace inverters and servo drives and commission them.
Operation
We renew operator panels so that operation and diagnostics match the new controls.
Safety technology
We design the safety technology to DIN EN ISO 13849 and validate it.
CE after modification
After a substantial modification, whoever carried out the modification is regarded as the manufacturer. We assess the modification and prepare the documents for CE marking.
What the retrofit gives you
Your machine runs again with components that are available. Faults can be diagnosed by remote access, and you get up-to-date documentation for the renewed controls and safety technology.
Fewer failures thanks to available parts
Available components, backed-up software versions and documented spare parts: if a component fails, a replacement can be obtained and the program version can be restored.
Remote access, diagnostics and data analysis
Via remote access we see messages and signal states. You evaluate process and machine data yourself.
Safety technology to the current state of the art
Before the modification, we define with you which safety technology will be renewed. We implement these parts to the current state of the art and document them for commissioning.
Up-to-date digital documentation
You receive updated circuit diagrams, software versions and project documents in digital form.
How a retrofit works
Technical inventory
On site we assess condition, fault history, documentation, spare parts, interfaces and possible modification periods.
Preparing modification packages
We back up the machine's programs and parameters, put together modification packages and plan downtime windows, material, software and restart tests.
Modification in our hall or at your site
We modify the machine in our assembly hall in Wörth an der Donau or directly in your production.
Handover and commissioning
We test the modified functions, put the machine back into operation in a controlled manner and hand over software, backups and documentation.
Frequently asked questions about machine retrofits
The questions we hear most often before a retrofit.
When is a machine retrofit a better choice than a new machine?
A retrofit pays off if the mechanics are in good condition and the machine can continue to produce your parts in the required quality.
This is usually the case when it is mainly the controls, drives or missing spare parts that limit operation, in other words areas that can be renewed individually.
Compared with a new machine, a retrofit makes economic sense if the total costs over the planned service life are lower and the modernised system meets your requirements.
Which components do you modernise and what can be retained?
We modernise controls, HMI, electrical engineering, drives, sensors, mechanics, machine safety, diagnostics and remote access, individually or together depending on the machine.
What remains is whatever is in good condition, performs its function and can be connected cleanly to the new technology, often the machine bed and guideways.
If the machine is linked to peripheral equipment or a higher-level system, we align the modification packages and the limit of our system responsibility accordingly.
Is a retrofit possible without complete circuit diagrams and programs?
Yes, provided that programs and data can be backed up or reconstructed. We first check which circuit diagrams, programs, parameters and machine information are available.
If something is missing, we additionally survey the machine, analyse the functions and document them. We show this effort separately.
To plan migration and tests, we need access to the machine.
How do you plan downtime and restart?
We plan the downtime window based on the modification work, the prepared hardware and software and the necessary restart tests.
We prepare hardware and software before production stops.
Before production starts, we test the modified functions and coordinate the restart with your team.
Which factors determine the overall effort and the costs of a retrofit?
The effort is mainly determined by the condition of the machine, the quality of the documentation, the desired functions and the integration into your installation. The age of the PLC plays a smaller role.
Hardware, software access, licences, mechanical adaptations, safety measures and testing effort influence the costs.
After the inventory, you receive a description of the modification packages, open points and possible downtime windows. This gives the cost framework.
What information helps with the initial assessment?
- Send us what you have. Even incomplete information is enough for an initial enquiry.
- Manufacturer, year of construction and types of controls and drives, if known.
- Existing photos, circuit diagrams and backups.
- Known faults and desired changes, plus production volume, variants and interfaces, if known.
- Location, contact person and possible downtime windows, if already foreseeable.
Check a retrofit for your existing machine
Tell us the machine type, year of construction, controls and desired functions. Photos, existing diagrams, program versions and the fault history help us assess the condition.
Simon Niklas
Mechanical engineer, M.Sc.
+49 941 56956720[email protected]
“Good engineering proves itself in day-to-day production. That is why we combine technical planning with a close understanding of process, operation and maintenance.”
Book a consultation