How to digitize existing machines - without replacing them
Modern industry is talking about digitalization, predictive maintenance and energy efficiency. However, many production companies work with machines that are mechanically reliable - but hardly digitally networked.
This is exactly where Retrofit to.
Retrofit means:
Existing systems will be retained - but will be expanded with modern measurement technology and data acquisition.
This creates transparency, predictability and efficiency without the need for a completely new purchase.
Why retrofitting is necessary at all
In many production halls, machines have been running reliably for years or decades. Mechanically robust. Technically well-rehearsed.
What is missing, however, are answers to crucial questions:
- How high is the actual capacity utilization?
- Where do unnecessary energy losses occur?
- Which components are currently wearing out?
- Why do unplanned downtimes occur?
Without measurement data, these questions remain unanswered. Decisions are then based on gut feeling - not on facts.
What does retrofit mean in concrete terms?
Retrofit is not a new machine. It is a Digital extension of your existing systems.
The principle is simple:
- Measure sensors, what was previously invisible (temperature, vibration, current, power).
- A Measurement data system records and stores these values.
- The data is analyzed and presented in an understandable way.
- You will automatically receive a message in the event of deviations.
Your machine remains technically unchanged - it simply becomes „data-capable“.
What is measurable?
Typical measured variables are
- Temperatures (e.g. on bearings or motors)
- Vibrations (early indications of wear)
- Electrical power and energy consumption
- Load profiles and runtimes
- Process values from existing control systems
This makes visible what was previously hidden.
How does this benefit you in everyday life?
1. less unplanned downtime
Increases in vibration or temperature indicate problems at an early stage.
They react before a system fails.
2. plannable maintenance
Maintenance is no longer carried out „according to calendar“, but according to actual condition.
3. transparent energy consumption
They recognize which machine consumes how much energy - and why.
4. better decisions
Production and maintenance managers work with real data instead of guesswork.
How does retrofitting work?
Retrofit takes place:
- Modular - Step by step
- During operation
- Without interfering with the existing control system
- With clear separation of machine and IT network
Retrofitting can start with a single machine and later be extended to the entire machine fleet.
From measured value to information
Data alone does not help. The decisive factor is the evaluation:
- Automatic limit value monitoring
- Trend analyses
- Early warning messages via push notification or e-mail
- Visualization on PC, tablet or smartphone
This turns figures into concrete recommendations for action, which can be analyzed and linked to other applications without compromising security.
For whom does retrofitting make sense?
Retrofitting is particularly worthwhile for companies that:
- want to continue using robust existing machines,
- want to avoid investment costs for new systems,
- pursue energy or sustainability goals,
- want to professionalize their maintenance,
- need transparency for audits or documentation.
These questions will quickly give you clarity:
- Do you really recognize what is happening in your systems?
- Are you already using all available machine data to make better decisions?
- Do you know at an early stage when disruptions or deviations are about to occur?
- Could your existing systems work even more efficiently if the right data were available?
- And how much optimization potential remains undiscovered today?