Automation & robotics
Industrial automation retrofit engineering
Engineering for upgrading existing automation, replacing obsolete controllers, drives, HMIs and panels while keeping machines productive and preserving the process know-how built into the original system.
Overview
Automation retrofits address equipment that still works mechanically but relies on obsolete or unsupported controls. Typical work includes migrating PLC programs to a current platform, replacing HMIs and drives, upgrading networks, rewiring or replacing panels and adding sensors or safety functions. The existing logic and operating sequence are documented first so behaviour is preserved or deliberately improved. Retrofits are planned to fit production shutdowns and are commissioned in stages where possible to limit downtime.
Planning a retrofit
Collect the existing program backups, drawings and device lists, and identify known faults and desired improvements. Agree the migration approach (like-for-like or functional upgrade), the shutdown window, test and fallback plans, and the documentation and training needed after cut-over. A survey of the installed hardware confirms what can be reused.
Range overview
- Types and variants
- PLC Platform Migration
- HMI Replacement
- Drive Replacement
- Panel Rewiring or Replacement
- Network Upgrade
- Features
- Existing System Documentation
- Program Migration
- Staged Cut-Over Planning
- Fallback Planning
- Updated Drawings and Training
Exact specifications depend on the variant, material and size. Confirm ratings and certification against the datasheet or with our engineers before ordering.
Applications
- Obsolete Controller Replacement
- Machine Life Extension
- Control System Standardisation
Industries
- Manufacturing
- Water and wastewater
- Material handling
- Packaging
Information that speeds up a quotation
Share what you know. Anything you are unsure of can be marked “not known” — our engineers will help confirm it.
- Site conditions
- Utilities
- Performance target
- Constraints
- Proposal scope
Need a datasheet?
Add this family to your enquiry list and mention the variant — we will send the relevant technical documents.
Automation engineering services
Related and alternative families
PLC programming and commissioning
PLC programming and on-site commissioning for new and upgraded machines and process systems, from control logic development and simulation through I/O checks,…
Automation control-panel design and assembly
Design and assembly of automation control panels, from electrical schematics and component selection through enclosure layout, wiring, labelling and pre-dispatch checks, for…
Controls maintenance and troubleshooting
Maintenance and troubleshooting of industrial control systems, including PLCs, drives, HMIs, sensors and control panels, to diagnose faults, restore operation safely and…
Automation system integration and testing
Integration and testing of automation systems, bringing together controllers, drives, HMIs, robots, instruments and plant software, and proving that the combined system…
Related solutions and guides
Frequently asked questions
What do you need to assess a controls retrofit?
Send the existing PLC and HMI program backups if available, electrical drawings, a list of drives and devices, photographs of the panels, and a description of current problems and desired improvements. Indicate the shutdown windows available so a realistic migration plan can be prepared.
What if the original program or drawings are missing?
The system can still be retrofitted, but more survey time is needed to trace wiring, record I/O and observe the machine's operating sequence. Experienced operators and maintenance staff are a valuable source of information. Missing documentation should be flagged early because it affects scope and schedule.
Ready to specify industrial automation retrofit engineering?
Send the details you have — quantities, sizes, drawings or a part number. Unknowns are fine.