Retrofitting systems and machines

Economically efficient through targeted modernisation

By retrofitting your conveyor systems, we bring your existing systems up to the latest state of the art without the need for a completely new purchase. In many companies, older systems run reliably, but over time both the efficiency requirements and the costs for maintenance and spare parts increase. Our retrofit offers an economically attractive solution for modernising your existing machines and systems and making them future-proof.

Our experts analyse the current condition of your conveyor technology and develop customised modernisation concepts. The retrofit includes not only the replacement of outdated mechanical components, but also the integration of modern control systems and energy-efficient drives. In addition, innovative features such as improved automation or smart networking can be added to your systems. This enables you to make the material flow more efficient, minimise downtimes and increase ease of maintenance.

Another advantage of our retrofit process is compliance with current safety standards. Outdated systems often harbour safety risks that can be eliminated through targeted modernisation. This not only ensures a longer service life for your machines, but also a safer working environment.

Why does retrofitting make sense?

Increasing demands on efficiency, productivity and sustainability are increasingly pushing machines and conveyor systems to their limits. When the costs for maintenance and spare parts also rise, while legal requirements and technological developments are constantly evolving, the advantages of a retrofit become obvious. A retrofit offers an economically viable way of future-proofing existing systems instead of having to invest heavily in new equipment.

Advantages of a retrofit at a glance

Modernisation instead of new purchases: Existing systems are brought up to date through targeted upgrades instead of cost-intensive replacement.
Increased efficiency: Modernised systems improve the performance of your processes and production lines.
Industry 4.0-capable: Hardware and software updates enable seamless integration into modern, networked production environments.
Current safety standards: Modernisation enables you to meet current legal requirements such as occupational safety guidelines.
Energy savings: More efficient drive systems and modern control technology reduce energy consumption.
Future-proof supply: The retrofit ensures the availability of spare parts and avoids production downtime.
Sustainability: Extending the service life of existing machines reduces waste and saves resources.
Faster amortisation: In contrast to a new investment, the investment in a retrofit often pays for itself in a short time through reduced operating costs.

What does a retrofit involve?

Our experts analyse the current condition of your conveyor technology and develop a customised modernisation concept. The retrofit process includes various measures to increase performance and optimise efficiency:

Mechanical modernisation:
- Replacement of worn or obsolete components such as bearings, drive belts or guide systems.
- Upgrading to stronger or lighter materials to improve operational reliability.
- Conversion to energy-efficient drives to reduce power consumption and maintenance costs.
- Integration of retrofit systems into existing intralogistics or production systems.
Electrical modernisation:
- Conversion to modern control systems to meet the requirements of digitalisation, safety and modern communication systems.
- Integration of visualisation systems (HMI) for better communication and interaction between man and machine.
- Renewal of electronic components and electrical wiring to comply with current safety standards and reduce failures.
- Use of the latest control systems and modern bus systems to reduce the space required for electrical components, cables and wiring.

Retrofit of belt conveyors

A retrofit of belt conveyors offers an ideal opportunity to make existing conveyor systems more efficient, safer and more durable. Older belt conveyors are often no longer state of the art or have damaged conveyor belts or inefficient drives that cause high energy costs. By integrating new energy-efficient drives and replacing conveyor belts with improved material properties, we increase the performance of your belt conveyors.

Retrofit of slat-band chain conveyors

Hinged belt chain conveyors are often used to transport metal chips, punching waste or hot components. Over time, signs of wear on the chain links, bearings or drive elements can become noticeable and restrict operation. A retrofit of hinged belt chain conveyors includes replacing the hinged chains, drive components and guide elements to ensure reliable and low-maintenance use

Retrofit vs. new purchase - when is which option worthwhile?

A retrofit is a sensible solution if:

The basic mechanical structure of the system is still intact.
Modernisation with new control systems is possible.
Spare parts for the existing system are difficult or expensive to procure.
The production requirements have changed, but a new investment is not necessary.

A completely new purchase, on the other hand, is advisable if:

The system is severely damaged or has been outdated for decades.
The desired increase in performance cannot be achieved by retrofitting.
Legislative requirements can no longer be met by modernisation.

In both cases, TEGEL-TECHNIK is at your side as a contact partner and manufacturer of conveyor technology. Contact us, we will find the right solution for your requirements.

Challenges and solutions for retrofitting

Although retrofitting offers numerous advantages, there are some challenges that need to be taken into account during implementation:

Technical compatibility: New components must be compatible with existing old components.
Integration into existing processes: The retrofit must be planned in such a way that it affects existing processes as little as possible.
Software adaptation: The modernised machines must be programmed to be future-proof for connection to ERP or process control systems and the integration of modern communication systems.

Our specialists are with you every step of the way - from analysis and implementation to optimisation of your modernised system.

Retrofit as a future-proof solution

Our comprehensive retrofit solutions offer a cost-effective alternative to purchasing new equipment and help you to sustainably optimise your production and logistics processes. Targeted upgrades make your existing system more powerful, energy-efficient and future-proof - without the high costs of a new purchase.

Discover how TEGEL-TECHNIK can make your existing systems fit for the future - contact us for a personalised consultation.