Retrofit - Drive modernisation

Modern but nonetheless hip – simply retro and yet somehow beautiful. The popular retro trend could be described in exactly the same terms. But what exactly does "retro" mean for a machine? And what exactly is a retrofit?

Retro derives from Latin and means something like "backwards". I.e. a trend from an earlier period suddenly becomes very fashionable again. The English word "fit" is perhaps best translated into German as "passend". A retrofit, therefore, is when an old machine that is past its prime is reconfigured for current technical conditions. Here you will find out exactly how this works.

What is retrofit?

"A retrofit includes various measures aimed at increasing the efficiency and performance of the machine."

Norbert Süß, Head of Service, Retrofit at Baumüller

A retrofit includes various measures aimed at increasing the efficiency and performance of the machine. Both individual components and complete drive systems can be upgraded. Often a machine controller will be upgraded and a modern operating unit (HMI) will be installed. Modern digitization tools can of course also be added for remote service or a diagnostic tool. All of these lend new shine to the old machine and enhance its performance enormously.

Reasons for retrofit

The replacement of obsolete components to meet the standards of state-of-the-art technology increases the productivity and energy efficiency of machines. With a retrofit, you as a system operator can benefit from significantly lower costs compared to the acquisition of new production systems. Here, the basic substance of your machine, usually very stable and high-quality, is preserved and in case of large machines there is no major expenditure incurred for replacements, such as for building a machine base, for example. The production downtime is thus greatly reduced thanks to a retrofit.

Advantages of a retrofit:

Modernize while saving energy
Saving energy can be that simple: With a well designed retrofit, it's possible.

Increase machine availability
High output needed: Fewer machine failures increase availability significantly.

Long-term increase in efficiency
We realize your individual requirements: This results in an increase in the efficiency of the machine that will last.

Improve replacement part availability
There for you in the future as well: Guaranteed replacement parts supply for your modernized machine.

Baumüller services:

Consultation

What drives you?
Do you want to increase your machine availability and modernize your system? We support you right from the start. Your individual requirements for the retrofit are our primary concern.

Our services:

Identification of customer requirements
Determination of the scope of the retrofit
Agreement on the overall scope and framework conditions

Concept

Conception phase
What products are perfect for your system? How can your machine fully realize its potential? Which retrofit concept makes the most sense for you?

Our services:

Technical analysis of the entire system, consisting of:
Review of existing control or automation systems (manufacturer-specific)
Creation of appropriate retrofit concepts
Preparation of a quote

Planning

Comprehensive scheduling
What is important to you? When should the retrofit be completed and how exactly should commissioning be carried out? All of this is laid out in the requirements specifications and functional specifications.

Our services:

Preparation of requirements specifications and functional specifications with customer
Planning of retrofit and commissioning of the machine in coordination with customers

Implementation

Engineering the system
We program your machine solution and take care of the procurement of all necessary components.

Our services:

Software development and testing
Project planning of circuit diagrams and drawings
Component ordering and if necessary control cabinet construction
Pre-commissioning and simulation
Retrofit of the machine

Commissioning

Step-by-step commissioning
We commission your system and test all components.

Our services:

Commissioning consisting of:

Installation testing
Hardware and software tests
Parameterization and optimization of the entire machine
Production assistance

Acceptance testing

Handover of the completed project
The retrofit was successfully completed. You can now proceed with acceptance testing.

Our services:

Handover of project documentation
Acceptance of implemented project with the customer
Preparation of acceptance log

Service

At your side 365 days a year
Preparation of a long-term maintenance and service concept – to maintain your productivity.

Our services:

Fast replacement part supply
24/7 hotline
Remote service
Continuous service (inspection, maintenance)

Manufacturer-specific solutions for modernization

Regardless of manufacturer, we offer you tailored and multi-level solutions for modernization of your electrical drive systems. With new drive components and control solutions you will quickly achieve greater flexibility and increase the productivity of your system – and while keeping investments at a manageable level. We equip existing machines with the most modern drive systems, control technology and user interfaces, thus allowing high system availability and process reliability.

Retrofit examples with different machine types

1. Extrusion machines

Common reasons for retrofitting extrusion systems include energy savings (in some cases up to 50 percent is possible) and replacement part availability. Because of in some cases very high energy savings, the investment in a retrofit often pays for itself in two years.

Your benefits at a glance:

Significant savings in energy consumption
Reduced space requirements of your machine
Low-maintenance drive elements for increased availability of your machines
Increased overall efficiency of the drive system
PLC in the drive and external temperature regulation
Replacement part availability

2. Printing machines

Common reasons for the retrofit of printing machines are replacement part availability and machine availability. As printing machines have a very robust design, there is no need to replace the machine. In these cases a retrofit or a partial retrofit is entirely sufficient to achieve the productivity of a current machine.

Your benefits at a glance:

Time and cost savings through modernization instead of acquiring a new machine
Future security through guaranteed replacement part and service availability
Increased reliability through modernized technology

Retrofits of electrical motors and converters

With new drive components you will quickly achieve greater flexibility and increase the replacement part availability of your system – and while keeping investments at a manageable level. Retrofitting existing machines to state-of-the-art drive systems allows high machine availability and process reliability.

Optimized solutions according to plan

After an inventory and analysis of currently installed drive technology, we will create a detailed quote for your company covering your optimized drive systems for the retrofit.

Based on your requirements, we will plan and define parameters for a drive system outfitted with the latest technology. In addition, we offer, along with the drive modernization, detailed training of your personnel in the new system so that you can enjoy the benefits of the drive modernization.

» GOAL: Increased efficiency of your machines and systems

Your benefits

We handle the entire project execution for drive modernization – service from a single source
Longer service life for your machine with the installation of modern technology and long-term component availability
Increased availability of your machine through reduced likelihood of failure due to wear and tear
Reduction of operating costs through the use of modern and reliable drive components for automation
Increase in energy efficiency of your production through modern and low-consumption drive systems
High replacement part availability
High product quality