Industrial Automation Retrofitting & Control System Upgrades
Modernise Existing Production Equipment Without Replacing It
Replacing an entire production line is not always necessary when performance issues or obsolescence arise. In many cases, industrial automation retrofitting can restore reliability, improve efficiency and extend the working life of existing machinery.
Retrofitting involves upgrading the control systems, drives, software and supporting infrastructure of existing equipment. Instead of replacing mechanically sound assets, manufacturers can introduce modern automation technology that improves performance while keeping disruption and capital expenditure to a minimum.
As an experienced Industrial Control Systems Integrator, we support manufacturers with practical, well-planned upgrades that improve system capability while maintaining continuity of production.
How Automation Retrofitting Works
Every retrofit project begins with a structured technical review of the existing system. This often includes an industrial drive system analysis, assessment of the control architecture and identification of obsolete components.
From there, a clear upgrade strategy can be developed that aligns with production requirements, available downtime windows and long-term maintenance considerations.
Automation retrofit projects commonly include upgrades across several areas of the system.
PLC Migration and Control System Upgrades
Many manufacturing sites still rely on control platforms that are reaching the end of their supported lifecycle. Through PLC migration and upgrades, legacy controllers can be replaced with modern hardware that offers greater processing capability, improved reliability and better integration with plant systems.
These production line control upgrades allow manufacturers to maintain existing mechanical equipment while significantly improving operational visibility, diagnostics and maintainability.
Legacy Drive System Modernisation
Drive technology has developed considerably over the past two decades. Older motor control systems can limit machine performance and consume more energy than modern alternatives.
Through legacy drive system modernisation, including VFD retrofit services, existing motor control systems can be upgraded to provide:
- Improved speed control
- Reduced mechanical stress on equipment
- Lower energy consumption
- Greater process stability
An energy efficient motor control retrofit can deliver meaningful operational savings while improving machine performance.
Managing Automation Obsolescence
All automation systems eventually face component obsolescence. Controllers, drives, servers and operator workstations will ultimately become unsupported by their manufacturers.
Effective obsolescence management for automation allows these components to be replaced in a planned and controlled way, avoiding unplanned downtime or emergency replacement.
Typical activities include:
- Controller replacement and platform upgrades
- Control panel modernisation
Planned upgrades help maintain system stability and ensure continued availability of critical spare parts.
Why Retrofitting Makes Commercial Sense
For many manufacturers, automation retrofitting offers a practical alternative to replacing entire production systems.
Key advantages include:
- Improved efficiency
Modern control systems allow machines to operate more consistently and efficiently. - Reduced downtime risk
New components provide improved reliability and better diagnostic capability. - Lower capital expenditure
Retrofitting allows mechanically sound equipment to remain in service. - Energy savings
Drive upgrades and improved motor control can significantly reduce power consumption. - Future flexibility
Modern control platforms provide a foundation for further automation improvements.
Automation REtrofitting FAQs:
Industrial automation retrofitting is the process of upgrading the control systems, drives, and software within existing machinery to improve performance, reliability and efficiency.
Instead of replacing mechanically sound equipment, manufacturers can modernise outdated automation components such as PLCs, motor drives, operator interfaces and industrial networks. This allows production systems to benefit from modern technology while retaining the original machine structure.
Fletcher Moorland is available to support you with PLC upgrades to full automation retrofits, our engineering team delivers practical control system modernisation for manufacturers locally and nationwide. Based in Stoke-on-Trent, we support industry across Staffordshire and across the whole of the UK.
Discuss your automation upgrade with our engineers on 01782 411021
Contact Us
Please fill in the contact form to get in touch with us or contact us on the relevant channels below.
Fletcher Moorland Ltd.
Elenora Street
Stoke-on-Trent
Staffordshire,
ST4 1QG
Opening Hours:
Monday - Sunday: Open 24 hours
