Retrofit
Retrofit
We specialize in upgrading existing control systems with newer technologies to improve functionality, reliability, and efficiency without requiring complete turnkey system replacement. Our retrofit solutions revitalize proven machinery by replacing outdated PLCs, CNC systems, and control panels with modern equivalents that preserve your existing physical infrastructure.
Contact us at (717) 637-5991 to discuss your control system retrofit needs
Begin Your Retrofit Project
From initial assessment to final commissioning, our team provides the expertise needed to successfully modernize your control systems.
Phone: (717) 637-5991 Email: eew@elsnereng.com
Comprehensive Retrofit Solutions
Our control system retrofits encompass multiple technologies:
- PLC System Upgrades: Replacing obsolete programmable logic controllers
- HMI Modernization: New touchscreen interfaces with intuitive controls
- Drive System Updates: Converting outdated DC systems to AC vector drives
- Control Panel Rebuilds: Modern electrical components in existing enclosures
- Network Integration: Adding industrial ethernet and remote access capabilities
- Safety System Updates: Bringing equipment to current safety standards
Each retrofit solution is custom-designed to address your specific equipment challenges and operational goals.
Schedule a consultation to discuss your retrofit requirements
The Retrofit Process
Our structured approach creates successful control system modernization:
- Current State Assessment: Evaluating existing systems and documentation
- Requirements Analysis: Identifying needed improvements and capabilities
- Solution Design: Engineering the retrofit approach and selecting components
- Implementation Planning: Creating detailed conversion procedures
- Installation & Commissioning: Executing the retrofit with minimal downtime
- Operator Training: Ensuring staff proficiency with new interfaces
- Documentation Updates: Providing complete records of the modernized system
This methodical process delivers predictable results and smooth transitions to updated technology.
Applications & Equipment Types
Our retrofit expertise extends across diverse equipment categories:
- Converting Machinery: Slitters, rewinders, and packaging equipment
- Production Lines: Multi-stage manufacturing systems
- Material Handling Systems: Conveyance and sortation equipment
- Process Equipment: Mixing, coating, and treatment systems
- Custom Machinery: Specialized equipment with unique control requirements
- Legacy Products: Discontinued machines with obsolete controls
We have particular expertise with equipment featuring discontinued control systems from manufacturers such as Allen-Bradley, Siemens, GE, Modicon, and many others.
Tell us about your specific equipment for retrofit recommendations
Technology Partners
We work with industry-leading control system suppliers:
- Allen-Bradley/Rockwell Automation: CompactLogix, ControlLogix
- Siemens: S7-1200, S7-1500, TIA Portal
- Automation Direct: Productivity Series PLCs
- Mitsubishi Electric: iQ-R Series
- ABB: AC Drive Systems
- Parker: Motion Control Solutions
This variety of partnerships allows us to select the most appropriate technology platform for your specific requirements and budget considerations.
Benefits Beyond Control Systems
Our retrofits deliver advantages beyond basic controls:
- Production Data: Collecting and analyzing operational metrics
- Remote Monitoring: Secure access for troubleshooting and support
- Preventive Maintenance: Identifying potential issues before failures occur
- Energy Efficiency: Reducing energy consumption with modern drives
- Spare Parts Availability: Ensuring long-term component support
- Skill Set Compatibility: Aligning with your maintenance team's expertise
These additional benefits create ongoing value well beyond the initial retrofit investment.
Industries Served
Our retrofit solutions support manufacturers across multiple sectors:
- Paper Converting: Production and packaging equipment
- Pharmaceutical: Processing and packaging machinery
- Food & Beverage: Preparation and packaging systems
- Consumer Products: Assembly and packaging lines
- Industrial Manufacturing: Fabrication and assembly equipment
- Printing & Graphics: Press and finishing systems
Each industry benefits from our practical approach to control system modernization.
The Retrofit Advantage
Choosing to retrofit your equipment delivers multiple benefits:
- Cost Efficiency: 40-60% savings compared to new equipment purchases
- Reduced Downtime: Shorter implementation timeframes than full replacements
- Familiar Operation: Preserving mechanical systems operators already know
- Extended Lifespan: Additional years of productivity from current assets
- Improved Performance: Better accuracy and faster processing speeds
- Modern Capabilities: Access to current software functionalities
This strategic approach maximizes your return on existing capital equipment and brings control systems up to current standards.
Request Retrofit Information
Take the next step toward equipment modernization. Contact us today to discuss how our retrofit solutions can improve your operational capabilities without the cost of complete system replacement.
Frequently Asked Questions
Our clients commonly ask these questions about our retrofit services.
For additional information, please contact our engineering team directly.
Retrofit timeframes vary based on equipment complexity and the scope of modernization. Simple control system updates for standalone machines typically require 1-2 weeks of engineering followed by 2-5 days of implementation. More complex production line retrofits may need 4-8 weeks of engineering with phased implementation over several scheduled downtime periods. During initial consultation, we develop detailed project timelines that align with your production schedule. Many retrofits can be performed during planned maintenance shutdowns or slower production periods to minimize operational impact. Our team works in shifts when necessary to complete critical installations within tight timeframes.
Retrofit projects often improve machine safety by bringing equipment up to current standards. When modifying control systems, we evaluate existing safety circuits and upgrade them when needed to comply with current regulations such as NFPA 79, ISO 13849, or IEC 62061. Our documentation includes updated electrical schematics and safety validation records for your compliance needs. For machines requiring formal recertification, we coordinate with appropriate inspection agencies to verify the modified equipment meets applicable standards. Many clients use retrofits as an opportunity to address outstanding safety concerns with guarding, emergency stops, or access restrictions.
Our machine shop works with a wide range of materials including aluminum alloys, stainless steel, carbon steel, titanium, various plastics, composites, and specialty metals. Our material selection is guided by your specific application requirements and budget considerations. Our team stays updated on new material developments and can recommend alternatives that might offer cost savings or performance improvements for your application.
Performance improvements vary depending on the original system and retrofit scope, but typical gains include 15-30% faster cycle times, 10-25% reduction in scrap rates, and significant improvements in positioning accuracy and repeatability. Modern control systems provide faster scan rates, more precise motion control, and advanced diagnostic capabilities. Digital drives offer better acceleration control and more consistent operation across varying loads. Touchscreen interfaces make operation more intuitive and reduce training time for new staff. Beyond raw performance metrics, retrofitted equipment typically provides valuable production data for process improvement and maintenance planning that wasn't available with older control systems.
Our risk management approach includes several key elements to deliver successful outcomes. We begin by thoroughly documenting existing functionality before any modifications. Critical program logic and parameters are backed up where possible. Our engineering process includes detailed conversion plans with validation checkpoints. For critical production equipment, we may create simulation models to test new control systems before installation. Implementation plans include clearly defined rollback procedures in case unexpected issues arise. We maintain spare parts for critical components during the installation phase. Many retrofits can be staged with parallel systems running temporarily to allow for seamless cutover. This comprehensive approach minimizes risks associated with control system modernization.