Retrofit of legacy machines with modern drives, safety, and controls delivering higher uptime and safer operation.
Project Overview
Industry: Discrete Manufacturing
Scope: Drives Retrofit, PLC, Safety, HMI
• Obsolete components
• Safety upgrade requirements
• Limited panel space
• Tight commissioning window
• Risk analysis and I/O mapping
• Staged switchover plan
• Safety relays and wiring standards
• Operator training
• Modern drives (VFDs)
• PLC-based control
• Safety relays and interlocks
• HMI upgrades
• Standardized wiring practices
• Reduced downtime by 15–25%
• Safety incidents reduced by 20–30%
• Throughput increased by 10–20%
• Energy savings up to 10–18%
• Throughput: [value]% ↑
• Safety incidents: [value]% ↓
• Energy savings: [value]%
• Payback: [value] months
Danfoss • Schneider Electric • Rockwell Automation • Yaskawa
Looking for a similar solution?
All results are based on project-specific conditions and system configurations.