Retrofits & Plant Modernization for Industrial Facilities & Machinery
Upgrade existing systems without starting from scratch.
When is a retrofit a good idea?
Not every outdated system needs to be replaced. A Plant Modernization It is always worthwhile when a system is fundamentally operational but is reaching its limits due to outdated technology, a lack of spare parts, or new requirements. Added to this is a factor that is often underestimated: Outdated operating systems no longer receive security updates and become a target for attacks in the production network.
Typical situations in which customers reach out to us:
- The system is no longer meeting the required performance standards
- Spare parts are no longer available or are only available at a high cost
- The control system is outdated, and manufacturer support is being phased out
- New quality or environmental requirements are no longer being met
- Outdated operating systems such as Windows 7 or XP no longer receive security updates and become a target for attacks in the production network
- Maintenance and operation have become too time-consuming or too expensive
- No space or time for a completely new building
Facts and Figures on Plant Modernization
Retrofit or new construction?
Retrofitting is a good option if:
- the basic mechanical structure of the system is still intact
- if building a new structure would be significantly more expensive
- the production downtime at the new facility would be too long
- only parts of the system are outdated
- regulatory requirements can be met through targeted interventions
- Security vulnerabilities caused by outdated operating systems must be addressed
Building a new home makes more sense if:
- the entire plant structure must be fundamentally overhauled
- Capacity increases exceed the scope of the existing plan
- the operation and maintenance of the existing plant are permanently unprofitable
Our Retrofit Services
Why choose MEMBRAFLOW for your retrofit project?
- Experience with legacy SIEMENS systems: STEP 5, STEP 7, ProTool, WinCC flexible
- Analysis and assessment of the current situation prior to any intervention
- All from a single source: design, hardware, and programming
- EPLAN-based documentation of the modernized structure
- Minimal downtime through structured project planning
- Compliance with standards for European and international markets
The foundation of a successful retrofit
Talk to our retrofit expert
Frequently Asked Questions About Retrofits
Retrofit refers to the modernization and upgrading of existing machines or systems with the latest technology. The goal is to restore or improve the performance, availability, or compliance with standards of an existing system without having to build a completely new one.
Retrofitting is worthwhile if the system’s basic mechanical structure is still intact, spare parts are no longer available, new requirements can be met through targeted modifications, or building a new system would be significantly more expensive. During an initial consultation, we’ll work with you to determine which approach makes the most sense for your system.
We migrate existing systems with SIEMENS controllers: from STEP 5 and STEP 7 to TIA Portal, from ProTool and WinCC flexible to WinCC Unified, and older SIMATIC platforms to S7-1200 and S7-1500.
That depends largely on the scope of the project. Simple control system migrations that take just a few weeks to complete contrast with complex plant modernizations that can take several months. We define the project scope and timeline during our initial consultation.
In many cases, yes. We plan retrofit projects in a way that minimizes downtime. More complex projects require scheduled maintenance windows, which we coordinate with you.
Yes. After a retrofit, we update all system documentation using EPLAN so that the as-built condition is fully documented. This serves as the basis for future maintenance and expansions.
DE_DE 
EN 