Retrofit

A retrofit is the upgrade of an existing machine, line or installation by replacing or adding selected components, rather than replacing it entirely with a new one.

Many machines and installations in plants have a sound mechanical structure that could keep running for many years, but their electrical systems, automation or certain components are outdated. Spare parts are no longer available, breakdowns become more frequent, and the machine no longer meets current requirements for output, safety or data collection. A retrofit means keeping what still works well and replacing or adding what is outdated or missing.

The scope of a retrofit may include, among other things:

• automation: new controllers, operator panels, sensors and software,
• drives: new motors and variable frequency drives, which allow smooth speed control and use less energy,
• mechanical components: valves, pumps, agitators or seals,
• safety: guards, sensors and safety systems that comply with current regulations,
• new functions: such as automated CIP cleaning, ingredient dosing or connection to a SCADA or MES system.

A retrofit is usually cheaper and faster than buying a new machine or building a new installation. It often requires no changes to the building and no lengthy downtime. Before making a decision, however, it is worth assessing the technical condition of the machine, because if its structure is heavily worn, a retrofit may not pay off.

Example: A laundry detergent plant has a filling line that has been running for over a decade. Its mechanical parts are in good condition, but the controller is outdated, spare parts for it are hard to find, and every change of bottle size requires several hours of manual machine adjustment. Instead of buying a new line, the plant carries out a retrofit: it replaces the controller and operator panel, installs new drives with variable frequency drives and adds recipes that store the settings for different bottles. The line continues to run on the same structure, and changeovers are cut from several hours to around fifteen minutes.