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.
Retain mechancially sound machinery
Maximise the value of your existing assets.
Reduce Unplanned Downtime
Improve reliability and keep production running.
Improve Energy
Efficiency
Modern controls and components consume less energy.
Controlled
Upgrades
Stay ahead of obsolescence with future proofed systems.
Modern control - trusted machine
Fletcher Moorland approach every system upgrade/retrofit with an initial detailed assessment of the existing automation control systems. We identify opportunities for improvement and advise of potential risks.
Our team then create a tailored plan taking into account your production requirements and planned downtime windows. Our aim is to provide the right solution with the minimal of disruption to your operations
PLC Migration & Control Upgrades
Make the move to modern controllers for increased performance, improved diagnostics and seamless integration with your existing systems
Drive System Modernisation
Retrofit VFDs and drive systems to achieve greater speed control, reduce mechanical stress and lower energy usage
Obsolescence Management
Plan the replacement of legacy controllers & drives as well as control panel modernisation where required.
A practical alternative to full replacement
Retrofitting and upgrading your automation and control systems delivers significant benefits, without the cost and disruption of a full replacement.
Lower Capital Expenditure
Increase the life of existing assets.
Reduced Downtime Risk
keep production running.
Energy Savings
Reduced running costs and carbon footprint
Future Flexibility
Adapt to changing requirements.
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.
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.
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
