Introduction
Industrial automation has developed incredibly fast, forcing companies to drive productivity, safety, and accuracy. Yet companies are usually faced with an important choice — do they retrofit their current systems or make completely new installations? Both options present different benefits based on cost, technology compatibility, and future plans. This blog discusses what retrofitting and new installations entail, their main characteristics, uses, and how to determine which one is better for your operation.
What is Retrofitting in Industrial Automation?
Retrofitting refers to adding new technology to existing machinery or control systems without replacing the whole setup. Rather than buying new equipment, companies incorporate newer automation parts—like sensors, PLCs, or HMIs—into their older systems.
Example: Upgrading analog control panels to digital PLCs or connecting legacy machines to the Internet of Things .
Advantages of Retrofitting:
- More cost-effective than complete replacement
- Least amount of downtime during installation
- Prolonged life of existing machines
- Faster ROI (Return on Investment)
- Increased safety, energy conservation, and accuracy
What Are New Installations in Industrial Automation?
New installations refer to designing and installing a brand new, state-of-the-art automation system from the ground up. This entails new hardware installation, wiring, software, and network setup according to the current industry standards.
Example: Installing a new automated production line complete with intelligent robotics, sophisticated control systems, and real-time monitoring.
Advantages of New Installations:
- Includes the most recent automation technologies
- Reduces failure and long-term maintenance risks
- Increases system integration and scalability
- Guarantees compliance with new industry standards
- Promises improved efficiency and digital integration
Retrofitting vs. New Installation
Feature |
Retrofitting |
New Installation |
|---|---|---|
| Initial Cost | Lower | Higher |
| Implementation Time | Shorter | Longer |
| Technology Upgrade | Partial | Full |
| Downtime | Minimal | Moderate |
| Lifespan Extension | Existing machinery reused | New setup lifespan |
| Scalability | Limited by old design | Fully scalable |
| ROI Timeline | Quick | Long-term |
| Ideal For | Existing plants with functional machines | New plants or major expansions |
Applications of Retrofitting
- Upgrading manufacturing factories with outdated control systems
- Adding smart sensors or IoT modules to old machinery
- Improving energy management systems
- Replacing marine automation panels and industrial controllers
Applications of New Installation
- Setting up automated production lines
- Integrating robotics in assembly or packaging
- Constructing new marine control systems or automation configurations
- Developing smart factory infrastructures with cloud connectivity
Selecting the Best Option for Your Company
Your decision relies on a number of deciding factors:
Budget: If budget is a constraint, retrofitting is best.
System Age: If equipment is outdated or unsafe, opt for a new installation.
Future Plans: For scalability and digitalization, invest in new systems.
Tolerance for Downtime: Retrofitting reduces downtime interruptions.
Pro Tip: Carry out a professional system audit to assess your current setup before making a decision.
Why Aeliya Marine Tech for Automation Solutions
We are experts at supplying diverse industrial and marine automation components — from sensors to PLCs and from relays to power supplies and PCB cards and controllers. Whether you need to enhance your existing system through retrofitting or have a brand-new automation installation, our used and refurbished products have been expert-tested to deliver optimum performance at reasonable rates.
Our services are:
- Supplying original, high-quality automation components
- Quick and global delivery
- Dedicated technical support and customer service
- Products from trusted brands like Siemens, Omron, ABB, Mitsubishi, Allen-Bradley, Honeywell, and more