- Siemens · Schneider Electric · Delta · LS Electric · Wecon
Machine retrofits and control-system upgrades
Many machines are mechanically sound but their controls are not: obsolete PLCs, missing programs, relay logic, worn wiring or spare parts that are no longer sold. Replacing the whole machine is expensive. Replacing the controls usually costs far less.
What a retrofit covers
We survey the machine, document what is there and design a new control system around the existing mechanics. We test the new logic before the shutdown, so the changeover on site is as short as possible.
Survey and documentation
We trace the existing wiring and I/O, record the nameplates and produce the drawings the machine never had.
PLC and HMI replacement
Classic relay control or an obsolete PLC replaced with a current PLC and touch-screen HMI, with spare parts available in Egypt.
Motion and drive upgrades
Old drives replaced and motion re-tuned for positioning and synchronization, as in our bottle printing retrofit.
Brand migration
Move from a discontinued or hard-to-source platform to Siemens, Schneider Electric, Delta, LS Electric or Wecon.
New features
Recipes, counters, clear alarms and data logging added in the same upgrade.
Planned changeover
New panel and program tested before the shutdown, and a step-by-step changeover plan agreed with your production team.
When a retrofit makes sense
- The PLC or HMI is obsolete and spare parts are hard to find
- There is no program backup or no drawings
- Old relays and wiring cause frequent faults
- You need recipes, counters, alarms or data logging on an old machine
What you receive
- Survey notes and I/O list of the existing machine
- New electrical drawings
- New PLC and HMI programs
- Changeover plan and on-site commissioning
- Briefing for operators and maintenance staff
Related projects
Industries
Packaging and labeling
1 projectPharmaceutical
1 projectCosmetics
1 project
Platforms we program and integrate
Brand names and logos belong to their owners. They are shown only to identify the hardware our engineers work with.
Frequently asked questions
Is a retrofit cheaper than a new machine?
Usually, if the mechanics are in good condition, because the controls are only part of a machine's value. After the survey we tell you whether a retrofit is worth it.
How long will the machine be stopped?
As short a time as possible. We prepare and test the new panel and program before the shutdown, so the on-site work is mainly installation, I/O checks and start-up. The exact stop depends on the machine, and we agree the plan with you in advance.
Can you retrofit an imported machine?
Yes. Imported machines often have the hardest-to-find spare parts. We document the existing system first and keep what still works.
Machine retrofits
Have an old machine worth keeping?
Send photos of the machine, the panel and the nameplates. We will tell you what a retrofit involves.
What we need to quote
You do not need everything on this list. Send what you have and we will ask for the rest.
- What the machine or line does, and what you want to change
- Photos of the machine, the existing panel and the nameplates of the motors, drives and PLC
- Drawings, an I/O list or the existing program, if you have them
- Preferred PLC and HMI brand, or no preference
- Supply voltage and frequency at the machine, for example 380 V, 50 Hz
- Plant location and target date
- Languages needed for the HMI screens and documents