Line Retrofit & Modernization
The steel is fine. The controls are twenty years old.
Well-built mechanics run for decades. Drives, controls and safety technology don't, and their spare parts disappear long before the machine wears out. We modernize lines that already earn their keep: new control architecture, current safety technology and added stations where volumes have grown. The work is staged into your planned shutdowns and implemented independently of the original machine builder. You retain proven mechanics and process know-how while reducing obsolescence risk.
From raw body to finished assembly.
One team answers for all of it.
Continuity
Cutover is planned into scheduled shutdowns. Production doesn't wait for the project.
Availability
Modern drives and controls reduce common failure points associated with aging and obsolete components.
Capacity
Added stations and shorter cycles raise output on a line that is already approved.
OEM Independent
We analyze, plan and implement independently of the original machine builder, subject to technical assessment.
We deliver the system.
You operate it.
High Speed Assembly & Inspection Cells
Feeding System
A line is only as fast as its feed, and that holds for a modernized line too. Our feeding systems bring even delicate parts in gently, correctly oriented and exactly on cycle, at high rates. Protective coatings guard the part surface, and the simple connection to existing infrastructure gets production running quickly, which matters when the cutover has to fit a planned shutdown. Available as an option for every high-speed assembly system we build, from OKUMAT to the Modular Solution and the Transfer Solution.
Discover all High Speed Assembly Systems
Up to 300 parts a minute, and every one of them exactly where it belongs. Explore the high-speed assembly systems that turn many small components into finished products at a pace most lines never reach.
Downloads
We send datasheets and technical documentation on request.
Custom Solutions & Retrofit
System Retrofits
The mechanics are paid for. Keep them. A retrofit brings your system up to date without the cost of a new machine: modern control, current safety technology, higher availability. We work independent of the original manufacturer and typically migrate to a current Siemens control. As long as the mechanics are sound, the machine keeps earning. If the line also needs more capacity, there are System Upgrades.
Discover Custom Solutions & Retrofit
Your process is not in a catalog, and your machine should not be either. Explore how we build, extend and modernize production systems around what you make, from the first sketch to the last shift.
Downloads
We send datasheets and technical documentation on request.
One team from first sketch to a line that runs.
A process that has proven itself. One team plans, engineers and commissions your machine, and hands it over turnkey, ready to run, in the shortest possible time.
Planning
Concept, material flow and scope, defined with you before the first drawing is released.
Engineering
Mechanics, controls and process, designed as one system and simulated before the build.
Realization
Build, installation and commissioning at your plant, then handed over ready to run.
Frequently Asked Questions
When is a retrofit worth it?
When the mechanics are sound and the controls are not. Many lines still run on control generations that are only available as spare parts today, such as SIMATIC S7-300 since October 2025. A retrofit removes that risk at a fraction of the cost of a new machine.
Do you retrofit machines from other builders?
Yes. We analyze the machine, plan the measure and implement it independently of the original machine builder, subject to technical assessment. We typically migrate to a current Siemens control.
Can you add stations to a machine that is already running?
Yes. We extend existing machines with additional stations, processes or capacity. Preparation runs in parallel to production, and installation is scheduled into your planned shutdowns.
Can older machines be connected as well?
Yes. Machines without modern interfaces are connected through a control retrofit or an edge gateway. Your existing equipment becomes part of the same data flow as your new systems.
Can you integrate new systems into an existing line?
Yes. Our customers already run highly developed production, so we modernize and extend it. We add capacity and new stations without replacing the whole line. Scope is defined per project during planning.
Still have questions? Get in touch with our support team and we'll
discuss your unique requirements.
Does an upgrade require a new conformity assessment?
Only if the change counts as a substantial modification under EU machinery law. We assess every upgrade, update the risk assessment and handle the conformity documentation where required.
Are your machines CE marked?
Yes. Every machine for the European market is built on a documented risk assessment and ships with CE marking and a declaration of conformity. From January 20, 2027, this follows the new EU Machinery Regulation 2023/1230. For North America, we build to the applicable electrical and safety standards on request.
How do you prove a machine meets spec before it ships?
In a factory acceptance test (FAT) at our plant, with your parts, at full rate. We document output, capability and reject handling. After installation, a site acceptance test (SAT) confirms the same results on your floor.
Still have questions? Get in touch with our support team and we'll
discuss your unique requirements.
How long is production down during a retrofit?
As briefly as possible. Control cabinets are built and tested in advance, and the cutover is staged into planned shutdowns. For a prepared control replacement, three days of downtime is a realistic target.
What happens after delivery?
Service continues after commissioning: support, spare parts, and upgrades to existing systems. Scope is agreed per system.
How long are spare parts available?
Every machine ships with a spare parts list and a recommended stock for your site. We keep wear parts available and support our machines with spare parts for at least ten years.
Still have questions? Get in touch with our support team and we'll
discuss your unique requirements.
Process System Technologies
Anton-Grimmer-Straße 4
73466 Lauchheim
Germany
