NEW LIFE FOR OLD MACHINERY
“When we speak of retrofitting, we are talking about giving machine tools a second chance, one that will last just as long as the first,” explains Mr. Ralf Glatzeder, Head of Reman at Liebherr-Verzahntechnik in Kempten, Germany. At Liebherr, “reman” stands for “remanufacturing”, the complete reprocessing of a machine to the standard of a new one. This is also the goal of retrofitting, which involves upgrading a machine with new technology and components. In addition to automation, artificial intelligence and digitization, with sustainable production now long considered a key competitive factor.
Retrofitting Pays Off, in More Ways Than One Retrofitting is for more than simply the inexpensive alternative to a new purchase. Instead, it represents a strategic investment, particularly in the sustainability of those companies from the machine tool industry currently under pressure from the current economic climate and thus more cautious when it comes to investment. Instead of acquiring brand new machinery, key components such as CNC controls, drives, sensors or Industry 4.0-capable interfaces are updated. Precision, process stability and productivity are increased, while access is provided to digital services such as condition monitoring or networked production control.
Retrofitting also pays off in terms of energy efficiency and sustainability: consumption values are drastically reduced through the replacement of old drives and motors, which in turn lowers both operating costs and carbon emissions. At the same time, valuable resources are spared as the existing machinery remains in use and is not replaced by entirely new models. The machinery is also adapted to current safety standards and machine directives, not only meeting legal requirements but improving employee safety standards too.
In economic terms, retrofitting brings several benefits for companies. According to Mr. Glatzeder, depending on the situation, investment costs can be reduced by at least a third compared to a new acquisition, sometimes significantly more. There are far less downtimes due to the generally shorter retrofitting phase, while the payback period is noticeably curtailed. In a time of global supply chain issues and economic uncertainties, retrofitting also allows for greater planning security.
Retrofitting thus combines enhanced technical performance with economic reason, along with environmental responsibility and a clear contribution to sustainability. It is a tool used by companies to improve their competitiveness even in difficult times and to set the course for a sustainable production.
