Why retrofit instead of replace?
Replacing a working system means new investment, new integration work, and extended downtime. A conveyor system retrofit upgrades the components that matter most, controllers, drives, safety systems, while keeping the mechanical structure you already trust. Most customers see a shorter payback period than a full replacement.
Your Key Benefits at a Glance
Retrofitting allows you to significantly extend the service life of your existing machines and production lines. By replacing outdated or worn components and upgrading mechanics, electronics, and software, your equipment can operate reliably for many additional years — without the cost and disruption of a complete replacement.
Modern control systems, drive technology, and sensors optimize machine performance and process stability. Retrofits improve cycle times, reduce scrap, and increase overall equipment effectiveness (OEE), enabling your production to run faster, smarter, and more efficiently.
Aging machines often pose a risk of unexpected breakdowns due to obsolete or failing components. Retrofit solutions replace critical parts with current, readily available technology, minimizing unplanned downtime and ensuring stable, predictable production.
Energy-efficient drives, optimized control systems, and modern components reduce power consumption and waste. At the same time, extending the life of existing machines conserves resources and lowers the environmental footprint of your production.
Obsolete components and discontinued spare parts can quickly become a major operational risk. Retrofitting replaces outdated technology with modern, standardized components, ensuring long-term availability and simplifying maintenance and spare parts management.
Retrofits enable the integration of digital interfaces, connectivity, and data acquisition. This allows for Industry 4.0 applications such as monitoring, process optimization, and predictive maintenance — bringing legacy machines into the digital age.
Compared to purchasing new machines, retrofit projects require significantly lower investment while delivering comparable performance improvements. This results in faster payback times and a financially sound path to modernizing your production.
What a Ferag retrofit includes?
Every intralogistics modernization starts with a condition analysis of your system to identify weak points and obsolete components. From there, we replace discontinued PLC controllers and drive regulators, add remote access for faster troubleshooting, and modernize the operator interface for simpler parameter management. Retrofits can be scoped for a single machine or an entire line.
Signs your system needs a retrofit?
Common triggers include discontinued spare parts, increasing unplanned downtime, outdated control software, or the need to integrate with a new WMS. If any of these sound familiar, a retrofit assessment can clarify your options before a breakdown forces the decision.
How the intralogistics modernization process works?
After an on-site or remote condition analysis, we propose a scoped retrofit plan, execute the upgrade with minimal production interruption, and hand over a system tested to current safety standards. Our service team remains available for ongoing support after commissioning.
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Frequently asked questions
A condition analysis, replacement of discontinued controllers and drives, updated safety components, and a modernized operator interface.
Duration depends on system size and scope, from a few days for a single machine to several weeks for a full line, planned around your production schedule.
Yes. Retrofits are designed to upgrade discontinued electronic components while keeping the proven mechanical structure in place.
Yes. Our service team supports systems across all generations, including installations several decades old.
Ready to extend the lifetime of your machines?
Take advantage of our retrofit expertise to extend the lifetime and efficiency of your machines. Request a free initial consultation by filling out the form below — we’ll get back to you shortly.
