Retrofit: Digitizing Existing Machines Without Replacing Them
Maintain existing systems and upgrade them with modern measurement technology—without interfering with the control system and while the system is in operation.
Your machines are running. They’ve been mechanically reliable for years—often for decades. What they don’t provide is data. The actual utilization rate, where energy is being lost, and which components are currently wearing out—these things remain hidden. As a result, decisions about maintenance, investments, and efficiency are made based on gut instinct.
A retrofit closes precisely this gap. Sensors and data acquisition make visible what the system has previously kept hidden. No new purchases, no changes to the existing control system, during normal operation—and step by step, starting with a single machine.
Free and without registration—featuring three real-world examples from the pharmaceutical, energy, and mining industries.
What a Retrofit Reveals
Every unanswered question in the business has a measurable counterpart. The path from gut feeling to numbers is shorter than most people expect:
| Your question | What is measured for this purpose |
|---|---|
| How high is the actual capacity utilization? | Operating Times and Load Profiles |
| Where is energy being wasted unnecessarily? | Current, Voltage, Active Power per Machine |
| Which component is currently wearing out? | Vibrations on bearings and shafts, temperatures on motors |
| Why did the unplanned shutdown occur? | High-resolution process data, including the events leading up to and following the incident |
| Is the process still within the target range? | Pressure, flow, temperature, values from existing control systems |
This brings to light what was previously hidden—and turns assumptions into solid facts.
Four Steps to a Data-Ready Machine
- Trade shows. Sensors detect what no one has seen before: temperature, vibration, current, and power. We easily integrate existing signals from the control system via fieldbus or OPC UA.
- Record and save. A measurement data system records the values in real time and stores them locally in the device—even if the connection to the server is lost.
- Evaluate. Threshold, calculation, and logic channels process the data directly at the measurement point. Trends, consumption, and status are displayed on a PC, tablet, or smartphone.
- Respond. If any discrepancies are detected, the relevant employees automatically receive a notification via email or push notification—before the issue causes a production stoppage.
The machine itself remains unchanged. It simply gains a memory.
What's Changing at Work
Fewer unplanned downtimes. Rising vibration levels or temperatures signal problems long before the system shuts down. You take action instead of reacting.
Maintenance based on condition rather than a schedule. Maintenance is performed when it is necessary—not too soon, not too late.
Energy consumption that can be attributed to a specific source. You can see how much each machine consumes and under what conditions. This forms the basis for efficiency measures and for compliance with ISO 50001.
Faster troubleshooting. Sporadic malfunctions are the most expensive. With high-resolution measurement data and historical records, you can identify the cause in hours rather than weeks.
Here's how the implementation works—and what we handle along the way
A retrofit is not a project that halts your production:
- Modular – Start with one machine, then expand to the entire fleet whenever it’s convenient
- During operation – without interrupting production
- Without interfering with the existing control system – the system's functionality remains unchanged
- With clean isolation from the power grid – The machine and IT networks remain separate; upon request, we can implement a completely network-independent standalone solution
And because retrofitting existing systems rarely goes according to the catalog, we provide everything from a single source: project planning, the right sensors and measurement technology, control panel construction, on-site commissioning, and training for your employees. When it comes to data analysis, our approach is „configure instead of program“—your team works with the system without having to acquire programming skills.
From the field
Bayer AG – Process analysis at a pilot plant. Temperature, flow rate, sealing pressure, current, and voltage in a sealing process: measured, visualized, and vulnerabilities identified. → Read the article
HSP – Heating Test Bench Modernized. The existing test bench no longer met the requirements. Instead of building a new one: more measurement channels, thermocouples, and fiber-optic sensors in a single system, including remote monitoring. → Read the article
TKDZ – Energy monitoring over kilometers. Data loggers installed in the tunnels of a mining operation, connected via Modbus and Profibus. Result: ISO 50001 certification and a monitoring system that is now also used for fault analysis. → Read the article
Is a retrofit worth it for you?
Probably yes, if at least one of these points applies to you:
- Your existing machines are in good mechanical condition, but they do not provide any data.
- They would like to postpone or avoid investing in new equipment altogether.
- You are working toward energy or sustainability goals and need reliable consumption data.
- Your maintenance program is based on a schedule rather than on condition.
- You need transparency for audits and documentation.
And the crucial question: How much potential for optimization remains untapped in your facilities today simply because the data is missing?
Let's talk about your investments. Briefly describe your situation to us—we’ll give you an honest assessment of whether and how a retrofit would be worthwhile for you.
Phone +49 2204 97685-0 · [email protected]
Frequently Asked Questions About Retrofitting
Does production have to be put on hold for the retrofit? No. The measurement system will be installed in parallel with the existing plant. A shutdown may be necessary only for connecting individual sensors and can be scheduled during planned maintenance windows.
What if our IT department doesn't allow network access? In that case, we'll implement a standalone solution. Our devices store measurement data internally and operate completely independently of your IT infrastructure.
Does this also work with very old control systems? Yes. Where signals cannot be read from the control system, measurements are taken directly at the machine. Where interfaces are available, we connect them via OPC UA, Modbus, PROFIBUS, or PROFINET.
Can we start small? That's exactly how it's supposed to work. A machine, a measurement system, initial findings—and then scaling up once the benefits become apparent.
When will the investment pay for itself? Counterquestion: How much does an hour of machine downtime cost you? As a rule, the investment pays for itself with just one or two avoided breakdowns.
Do our employees need programming skills? No. The systems are configured using dialog boxes. Your employees set up the reports, thresholds, and alerts themselves.