Automation
Retrofit

Sustainable solutions to modernise your production

Our team specializes not only in supporting new machines, but also in retrofitting and modernizing existing systems. By using modern technologies, we increase the efficiency, performance and service life of your systems, resulting in sustainable and future-proof operation. HEITEC offers comprehensive services from analysis to implementation. Our solutions cover the entire value chain: from mechanical, electrical, software and control level engineering to production, complete installation and commissioning. We support you in every phase and are the central point of contact for all interfaces.

From service definition to risk assessment

HEITEC accompanies you through the entire process: from the inventory and preparation of a detailed report to detailed specifications and the creation of functional specifications through to the planning and implementation of your projects. Our service includes the identification of optimization potential, budgeting and comprehensive conversion planning. We also offer training and production support to ensure smooth operation. Optionally, we can carry out a machine safety assessment, especially for existing machines. A risk assessment in accordance with EN ISO 12100 provides you with a direct overview of the safety status and need for action of the tested machine. We are also happy to guide you through the entire conformity process.

Modernise your automation systems for maximum efficiency

Modernise your automation systems with our retrofit programme. We take on the re-engineering of mechanics through to production and assembly, the complete re-engineering of circuit diagrams through to control cabinet construction and the complete redevelopment of software and visualisation, both for existing systems (brownfield) and for new systems (greenfield). Rely on our expertise to increase the efficiency and performance of your systems and make them sustainable.

Efficient and smooth commissioning of your modernised systems

Our team takes care of the complete installation of all mechanical and electrical work as well as virtual commissioning (VIBN). We take care of the software commissioning up to the Site Acceptance Test (SAT) and work closely with you to ensure smooth processes. During the start-up and production phases, we offer comprehensive support and guide you through each implementation phase. In this way, we ensure that your modernised systems work efficiently and reliably and increase your competitiveness in the long term. Rely on our expertise for the smooth running and success of your retrofit projects.

Your advantages from a retrofit by HEITEC

  • Stable production

    After a successful SAT, we don't leave you on your own. We not only provide maintenance and service contracts, but also advanced technologies for simplified maintenance and precise fault localization.

  • Conformity to standards

    Our team uses advanced testing and analysis procedures to verify the completeness of your documentation and confirm its compliance with current norms and standards, ensuring compliance with relevant requirements.

  • Increase in productivity

    By using modern components, it is possible to increase productivity with their technological potential.

  • Spare parts availability

    For retrofit projects, the focus is on long-term spare parts supply: we rely exclusively on hardware components that remain available for at least 10 years.

  • Safeguarding expertise

    Due to fluctuation (e.g. age-related), the expertise of existing old systems is leaving the company. Retrofitting and modernisation measures effectively counteract this.

Do you have any questions?

We are here for you! Send us your enquiry and we will get back to you shortly. We look forward to hearing from you.

Get in touch now

Retrofit
With a modernisation plan, the system operator can not only plan his investments, but all new standards for safety technology and the current Machinery Directive are also taken into account at the same time.
Tim Albuschies | Head of Automation Erlangen

Find out more about our projects

Convince yourself of our industry-specific expertise. Our successfully completed projects show how we work closely with our customers to implement cost-cutting, production-enhancing and customised solutions.

All references

  • Medical technology

    Development of a standardised test station

    To optimise product testing capabilities, our customer required a standardised test station capable of performing in-circuit and functional tests for a wide range of products. This station needed to accommodate various test fixtures and provide a streamlined, repeatable test process. By implementing this standardised test setup, our customer wanted to improve the efficiency, accuracy and scalability of product testing.
    read more
  • Packaging and pharmaceuticals
    Solupharm

    System modernization and administration without risk

    This project involved the virtualisation of the automation and IT infrastructure of Solupharm Pharmazeutische Erzeugnisse GmbH. The main task was to modernise an existing production line by converting physical IT resources into virtual machines to ensure greater flexibility, reliability and lower costs.
    read more
  • Special machinery
    Lamy

    Fully automatic laser setting system for fountain pen nibs

    HEITEC developed a fully automatic laser setting system for fountain pen nibs for the German market leader for writing instruments. In order to meet the high quality standards, it is necessary for each nib tip of a writing tip to be straightened. The two nib legs are to be straightened to a predefined gap dimension.
    read more
  • Railway and maritime solutions

    Mega Yacht (80 m)

    Planning, engineering and production of navigation and communication systems, as well as low-voltage switchgear. Planning of the entire cable system.
    read more
  • Packaging and pharmaceuticals
    Syntegon

    Central SCADA control system for pharmaceutical service providers

    Increasing the safety and quality of the media supply for aseptic filling of syringes, cartridges and vials.
    read more
  • Railway and maritime solutions

    Government vessels (86 m)

    Planning, engineering and production of navigation and communication systems, as well as low-voltage switchgear.
    read more
  • Special machinery

    Precise traceability through SAP integration

    Carl Schlenk AG is a leading international manufacturer of metal powders, effect pigments and metal foils. With a new building, Schlenk also wanted to reorganise its logistics processes in production with the aim of gaining an overview of material consumption and material receipts in real time.
    read more
  • Intralogistics

    Partial retrofit of an order picking warehouse

    It was becoming increasingly difficult to procure spare parts for an order picking warehouse from the 1990s, including the control technology based on Simatic S5, as the control components had been discontinued for some time. The risk of long, incalculable downtimes in the event of a component failure grew steadily. Continuous safe operation was no longer guaranteed. HEITEC was commissioned to analyse the current situation and the risk of failure and to carry out the retrofit.
    read more
  • Intralogistics
    Hengstenberg GmbH & Co. KG

    Retrofit of a high-bay warehouse using a model example (Hengstenberg, Bad Friedrichshall)

    Hengstenberg GmbH & Co. KG develops and produces sour, wine vinegar and delicatessen products and stores its products in a high-bay warehouse at its site in Bad Friedrichshall. Three storage and retrieval machines supply two storage areas, which can accommodate single or double pallets. The companies Artschwager & Kohl Software GmbH and HEITEC AG were commissioned to modernise the three storage and retrieval machines, the conveyor technology and the safety equipment in the final packaging, storage and canning areas as well as the warehouse management system.
    read more
  • Intralogistics
    Clinic Fulda gAG

    Retrofit of an AWT system (automatic goods transport)

    The AWT system at Fulda Hospital controls around 360 transport containers underground and away from the flow of patients, with the help of which the supply and disposal of each hospital ward is ensured. The modernisation was intended to ensure the availability of the AWT system in the future and find a solution for the problematic procurement of spare parts as well as enable future expansions of the system. In addition, the basic functionality of the system had to remain as unchanged as possible despite the implementation of modifications and troubleshooting in order to minimise the training requirements for the hospital staff.
    read more
  • Intralogistics
    Vacuumschmelze (VAC) GmbH & Co. KG

    Modernization of a high-bay warehouse

    The high-bay warehouse, built in 1980, has a capacity of 3,800 storage locations, which are divided into eight racks. Previously, the processes were controlled with SIMATIC S5 135U and operated via COROS. Many of the HW components were discontinued at the end of the 1990s and a continuous supply of spare parts was no longer guaranteed. In order to ensure the availability of the high-bay warehouse in the future, it was necessary to modernise the control and drive technology as well as the safety technology.
    read more
  • Special machinery
    Loparex Germany GmbH & Co.KG

    Retrofit of a film winder

    HEITEC AG was commissioned by Loparex Germany to modernise one of its existing film winders with the designation "Winder E27". A retrofit was necessary to ensure the operation of the system with increased availability, current safety standards and a guaranteed supply of spare parts for the future. This was based on the consideration that a retrofit can be more sensible for existing systems than replacing them with new ones, as it results in less downtime and lower costs. By replacing obsolete components and adding new, up-to-date technological developments, existing systems are brought back up to date. This reduces the risk of production downtime and employees can continue to work with the familiar technology, making extensive training unnecessary. A retrofit also has a positive effect on product quality.
    read more
  • Automotive

    Optimisation of cycle times with the help of the digital twin

    A leading international company in the fields of variable camshaft phasing units and transmission valves commissioned HEITEC to virtually commission an existing plant in order to identify potentials with the help of the digital twin on the basis of a cycle time optimisation measure and thus initiate targeted retrofit measures. In addition, technologies from the field of special machinery and plant engineering such as bulk material separation with 3D image recognition, belt and film conveying, new drive and clamping processes as well as software-in-the-loop with Siemens PLCSIM Advanced and Epson robot systems posed new challenges.
    read more
  • Packaging and pharmaceuticals
    Holopack packaging technology

    Automation of a pharmaceutical filling line

    Holopack Verpackungstechnik specialises in the contract filling of cosmetic and pharmaceutical products. Efficient filling technology plays a very important economic role here. Holopack was looking for a solution to increase production capacities in the manufacture of sterile and non-sterile, low to high viscosity pharmaceuticals. An intelligent automation solution with a batch management system was required to control the system - including a high-performance homogeniser.
    read more
  • Special machinery
    Renner labelling technology

    Automation of a labelling system

    Renner Etikettiertechnik is an internationally oriented supplier of professional labelling systems for the food and beverage industry. The automation specialist developed new technology components for the newly developed labelling system and integrated them into the overall system control. This was then tested on the digital model in order to recognise and rectify errors at an early stage.
    read more
  • Special machinery
    Duscholux

    Latest automation technology for Duscholux production systems

    Duscholux is one of the world's leading manufacturers of sanitary facilities. As a long-standing partner for the automation of production systems, HEITEC modernised the control technology. The aim was to further increase plant availability and production reliability.
    read more
  • Special machinery
    Vacuumschmelze (VAC) GmbH & Co. KG, Hanau

    Modernisation of a furnace line using a model example (Vacuumschmelze (VAC) GmbH & Co. KG, Hanau)

    VACUUMSCHMELZE (VAC) in Haunau develops, produces and markets speciality materials and products refined from them. The modernisation of the control and regulation technology was intended to increase the availability and operational reliability of five bell annealing furnaces. The systems were previously monitored and controlled via a centralised control system and a single operating and monitoring system. An important customer requirement was to be able to operate each furnace independently and to install an additional operating and monitoring system in the control room to manage and distribute recipes. In addition, the logging of process values was to be modernised and a convenient user administration system set up.
    read more
  • Special machinery
    Netsch Group

    Increased productivity through real-time communication with SAP

    The Netzsch Group is a globally active family-owned mechanical engineering and equipment manufacturing company. The company built a new production facility in Selb for the manufacture and assembly of devices for thermal analysis, thereby expanding its capacity by 60 per cent. As the devices are increasingly geared towards customised requirements, Netzsch has streamlined its processes and geared them more efficiently towards individual production up to batch size 1, quality and efficiency. To achieve this, all processes had to be networked with each other.
    read more

Our experts are near you

Our service portfolio ranges from automation and plant and special machine construction to electronics and end-to-end digitalisation solutions. Over 1,200 employees throughout the HEITEC Group guarantee expertise and customer proximity.

HEITEC offers end-to-end solutions, products and services in the fields of plant and special machine construction, automation, digitalisation and electronics - from digital models to 24/7 service.

Services at HEITEC