Automation
Modernizing legacy. Powering what’s next.
Modernization & Retrofits
Upgrading Legacy Systems for Next-Level Performance
Modernization and retrofits in the automation industry involve upgrading outdated control systems, hardware, and software with modern technologies to improve performance, reliability, and efficiency. These upgrades allow manufacturers to extend the life of existing equipment without the cost of full system replacement. Common updates include replacing legacy PLCs, integrating modern HMIs, and adding networked sensors for real-time data.
By modernizing infrastructure, companies benefit from reduced downtime, enhanced safety, and easier system maintenance. Retrofits also enable compatibility with new technologies, allowing for greater scalability and flexibility. This approach helps facilities stay competitive while meeting today’s production demands and future-proofing for growth.
What Automation Brings to Your Business
What is modernization and retrofitting in industrial automation?
Modernization and retrofitting involve upgrading outdated or legacy automation equipment with newer, more efficient technologies. This can include updating PLCs, HMIs, drives, sensors, and communication networks. The goal is to improve performance, reliability, and compatibility without the cost of completely replacing entire systems.
Retrofits help extend the life of existing equipment, enhance safety, and ensure the system meets current operational and regulatory standards, making them a cost-effective strategy for long-term productivity.
Why should a facility consider modernizing its automation systems?
Facilities should consider modernization to improve system reliability, reduce downtime, and maintain compatibility with current technologies. Older systems may lack support, spare parts, or functionality needed to keep up with modern production demands. Upgrading enables better performance, energy efficiency, and real-time monitoring while also addressing safety and compliance issues.
Modernization also supports future scalability, allowing facilities to adapt to new requirements without starting from scratch—ultimately protecting long-term operational continuity and investment.
What are the common components replaced during a retrofit?
Common components replaced during a retrofit include outdated PLCs, HMIs, motor drives, sensors, and communication networks. Electrical panels, control cabinets, and wiring may also be upgraded for safety and compatibility. Software platforms such as SCADA systems are often modernized to enable real-time monitoring, remote access, and data analytics.
These upgrades improve system functionality, reliability, and ease of maintenance, while allowing older equipment to integrate with newer technologies and support modern production needs.
Can legacy equipment be integrated with new automation technologies?
Yes, legacy equipment can often be integrated with modern automation technologies using protocol converters, updated controllers, or I/O modules that bridge the gap between old and new systems. This approach allows facilities to retain valuable machinery while gaining the benefits of modern features like data logging, predictive maintenance, and remote monitoring.
Integration must be carefully planned to ensure safety and reliability, but it’s a practical way to extend equipment life and minimize capital investment.
General Motors Assembly Line
Oshawa, Ontario
Our team recently completed a full control system upgrade for an automotive manufacturing assembly line producing high-volume vehicle chassis. The project involved replacing outdated PLCs with modern, networked controllers and integrating real-time data monitoring across welding, material handling, and inspection stations.
Additional Hardware / Software Highlights
Drives: Siemens SINAMICS S120 servos for precision fastening
Safety: SICK deTec4 light curtains, Pilz PNOZmulti safety relays
Network: Redundant PROFINET ring with Scalance switches (1 Gb/s)
Data Layer: MQTT Sparkplug B broker to cloud BI portal
Results at a Glance
20 % cycle-time reduction and 30 % drop in unplanned downtime
Full VIN-level traceability on welds, torque, and vision checks
Six-week shutdown delivered on schedule with zero lost-time incidents
This integrated stack future-proofs the line for EV chassis variants while giving maintenance teams real-time insight and one-click recipe changes.