10. December 2024
Many manufacturing companies have high-precision machines that are in perfect mechanical condition – but their CNC controls, electronics or software are outdated. This is where retrofitting comes in: the economical alternative to purchasing new equipment.
Instead of investing millions in new equipment, companies are modernising their existing machines – technically, electronically and in terms of software – and adapting them to the requirements of Industry 4.0.
Per definition Retrofit refers to the modernisation of existing machines or production systems, in which old components such as controllers, relays, electronics, drives or software are replaced with modern components.
The aim is to
The mechanical assemblies – i.e. spindles, axes and base frame – remain unchanged. This saves resources and ensures that proven mechanics continue to be used, while only the technological infrastructure is renewed.
A retrofit typically costs 30–50% of a new purchase, but offers almost the same range of services – with significantly shorter conversion times.
Modern control systems improve repeat accuracy and reduce energy consumption.
This is a decisive competitive factor, especially for lathes and milling machines.
The continued use of existing machine components minimises the ecological footprint – an important argument in the context of Industry 5.0.
For long-term reliability and standardized maintenance, new systems often rely on Windows-based CNC software solutions.
Retrofitting is particularly suitable for:
Companies such as HDC Hüttelmaier, Wabeco and medium-sized manufacturing companies use retrofit measures to achieve efficiency and precision on a par with modern new machines.
The machine is evaluated from a technical perspective: mechanics, electronics, control system and software. This involves checking which components can be retained.
Based on the requirements, new CNC control systems, operating elements and electronic components are specified – for example, based on modern platforms from Siemens, Beckhoff or ProCom Automation.
Old components are removed, and the new systems are installed, wired and tested.
The control software is tailored to the specific application – e.g. tool parameters, machining cycles and cutting strategies.
After a successful test phase, machine operators are trained and the final handover takes place, including documentation and a support concept.
Discover our software solution ergoCNC – the intelligent control system for cutting machines.
Despite the advantages, there are also factors that should be taken into account when making a decision:
This objective comparison helps you to realistically assess the economic and technical benefits of CNC retrofitting in relation to potential costs.
A laser fine cutting system that was over 20 years old was equipped with a ProCom CNC control system that had worked reliably but was no longer technologically up to date with current systems.
The aim of the retrofit project was to keep the machine running productively and efficiently for at least another five years – with modern operation and high accuracy.
The modernised laser system now operates with a control cycle time of 80 µs, significantly improved ease of use and reduced maintenance intervals.
Thanks to the new control system, the machine could continue to be used in continuous operation – with increased process stability, data connectivity and remote support functionality.
| Criterion | Retrofit | New Machine |
|---|---|---|
| Investment costs | Approx. 30–50 % more cost-effective | 100 % |
| Implementation time | 2–8 weeks | 3–9 months |
| Production downtime | Minimal due to step-by-step conversion | Complete |
| Service life extension | +5–10 years | 10–15 years |
| Flexibility & customisation | High (tailor-made) | Standardised |
CNC retrofitting is the smart alternative to purchasing new equipment.
You modernise your old CNC machine, increase productivity and efficiency – and bring your system up to the current Industry 4.0 standard.
Retrofitting is a tailor-made, reliable and economical solution, especially for small and medium-sized manufacturing companies.
A retrofit often significantly improves energy efficiency, as modern drives, controls and intelligent energy modes reduce consumption. Improved control technology and optimised motion sequences also reduce peak loads.
Stable networks, secure remote access, defined firewall rules and clear data interfaces are necessary for modern CNC controls. A prepared IT infrastructure enables smooth integration and later Industry 4.0 functions.
Important factors are proven project experience, availability of support, transparent documentation, compatibility with existing machine models and a clear project workflow. References from similar industries provide additional reassurance.
Through modern components and commercially available electronics, spare parts availability is secured in the long term. Standardised assemblies are easier to obtain and reduce the risk of machine downtime in the coming years.
Yes, modern CNC control systems meet all current ISO, CE and safety standards. This also applies to specific requirements in cutting technology, such as laser cutting systems or water jet systems.
Retrofitting with our ProCom CNC300-PX control system demonstrates how important it is to modernise existing systems in order to ensure efficiency, precision and competitiveness. With tailor-made solutions, we help you to exploit the full potential of your machines and secure your production capacities in the long term.
Discover how our products can future-proof your machines. Let’s work together to find out how we can take your production to the next level!
