Case study · Plastics processing
40 injection moulding machines, one data foundation
Heterogeneous controllers connected over OPC UA and Modbus, 90 percent less scrap.
Learn more →Retrofit
Retrofit existing machines
instead of replacing them
Older machines hold valuable production data, but often lack the interface. With OPC UA retrofit, protocol converters and edge gateways, we establish data connectivity without replacing the controller.
Request a retrofit
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Why retrofit comes before replacement
The most common objection to machine data collection in practice is: the plant is too old, the controller has no interface. In most cases that is not entirely true. Older controllers do speak protocols: Modbus, Profibus, S7-TCP, BACnet or proprietary fieldbus interfaces. A retrofit unlocks these protocols and converts the data into OPC UA or MQTT, the standards on which a consistent data foundation is built.
The difference in investment is significant. Replacing a controller costs between 20,000 and 200,000 euros depending on the plant, plus production downtime during the changeover. A retrofit that connects the same plant to the same data foundation typically costs a fraction of that.
The decision whether retrofit or replacement is more economical belongs in an ROI calculation. We carry this out within the potential analysis or the automation audit and recommend on the basis of the numbers, not from an installation preference.
Frequently asked questions about machine retrofit
Which controllers can be retrofitted?
Most common controllers from the mid-1990s onwards: Siemens S7 (S7-TCP), Beckhoff, Pilz, but also older PLCs with Modbus RTU or TCP. Edge gateways such as the SWIFT-BOX enable protocol conversion directly at the machine. A brief conversation will clarify whether your plant is retrofittable.
How long does a retrofit project take?
A straightforward retrofit that connects one machine via a protocol converter to an existing data foundation can be completed in one to three days. More complex projects with several machines and individual information models take several weeks. We quote the effort upfront.
What happens to the data after the retrofit?
The machine data goes into the data foundation, the system that already consolidates the other sources (ERP, MES, energy). From there it is available for analytics, dashboards, maintenance planning and AI applications. If no data foundation exists yet, we build one.
Case studies with retrofitted machines
Case study · Metalworking
Energy cost per order
Meter and machine data joined to order data: unit costs including energy.
Learn more →Equip existing machines with data, not replace them.
We verify that your plant can be retrofitted and implement the connectivity if it pays off.
Request a retrofitOPC UAopen standard
No replacementof the controller needed
Fixed pricequoted upfront
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