the customized automation solution
Vimotech realizes
Retrofit & Modernization of Production Systems
Upgrade control systems, reduce spare-part risks, and future-proof existing production equipment.
What we do
Modernizing Existing Production Systems
Industrial plants are often operated for many years. Over time, control systems, electrical components, and interfaces become outdated. Spare parts become harder to obtain, expertise is lost, and modifications to the equipment become increasingly complex.
We support retrofit and modernization projects – from analyzing existing systems to the step-by-step migration to current technology. We assess which components can continue to be used effectively and where targeted replacement offers economic advantages.
Wherever possible, we plan modifications around existing downtime windows to keep production interruptions to a minimum. At the same time, modern control systems, visualization solutions, safety technology, and inspection systems create new opportunities for expansion, diagnostics, and data utilization.
Your benefits:
- Reduced spare-parts and failure risks
- Less dependence on individual key personnel
- Improved expandability and data availability
- Shorter downtime during faults and modifications
- Higher system availability and long-term future readiness
The goal: Modernize existing production systems economically – with minimal downtime and a technical solution that remains maintainable in the long term.
Motivation
Technology ages. Production must keep running.
Production systems are often in operation for decades. While the mechanical equipment may continue to perform reliably, control systems, drives, sensors, and electrical components tend to age much faster.
Spare parts are discontinued, interfaces are missing, and expertise in older or less common systems is gradually being lost. As a result, even a single component failure can lead to prolonged downtime or costly repairs.
At the same time, system expansions, process improvements, and the integration of new functions become increasingly difficult.
Analyze Existing Systems
Existing control systems, electrical components, and interfaces are assessed in terms of condition, availability, and long-term viability.
We take into account spare-part risks, available documentation, required extensions, and potential dependencies on individual systems or key personnel.
Plan the Migration
Based on the analysis, we determine which components can remain in use and which should be replaced selectively.
The modernization is planned to make the best possible use of existing downtime windows while keeping production interruptions to a minimum.
Modernize the System
Control systems, drives, visualization, safety technology, and inspection systems are upgraded step by step and integrated into the existing production system.
The result is a production system that is easier to maintain, more flexible to expand, and technically sustainable in the long term.
ACtion instead reaction
Creating Long-Term Future Readiness
Not every existing production system needs to be completely replaced. By selectively replacing critical components, proven machinery can remain in operation while being upgraded to current technical standards.
A step-by-step modernization offers numerous advantages:
- Improved spare-part availability
- Reduced risk of unplanned downtime
- Less dependence on specialized expertise
- Easier maintenance and troubleshooting
- Better expandability
- Modern interfaces and data access
- New possibilities for visualization, safety, and inspection technology
Continue operating existing production systems economically while reducing the technical risks for the years ahead.
your industry, our expertise
Target group-oriented automation solutions from Vimotech
Steel and aluminum production
Automotive
Aerospace
Packaging industry
Components according to your requirements
Special control systems
Special applications, customized solutions, or older machine concepts often rely on less common control systems. As long as the equipment operates reliably, this is usually not an issue. However, once modifications, expansions, or faults occur, the dependence on individual specialists quickly becomes apparent.
Limited programming expertise, outdated development environments, or difficult-to-source spare parts can make even minor changes unnecessarily complex. As a result, optimization potential often remains unused and necessary modernization projects are postponed.
Vimotech works across different manufacturers and is accustomed to familiarizing itself with existing automation systems. We analyze the current solution, preserve the available know-how, and develop a practical path for maintenance, expansion, or step-by-step migration.
Regain the ability to maintain and develop even rare or outdated control systems – without unnecessarily replacing the entire production system.
Outdated or difficult-to-maintain control systems increase the risk of unplanned downtime and make modifications more complex. A targeted control system replacement creates a modern, long-term supported technical foundation.
The entire production system does not always need to be modernized at once. Depending on the size of the system and the available downtime window, we plan the migration step by step and coordinate the work with production. Existing functions are transferred, verified, and improved where necessary.
In addition to the PLC itself, we also consider visualization, drives, fieldbus systems, interfaces, and safety technology. This creates a consistent overall system rather than an isolated individual solution.
Reduce legacy dependencies, improve spare-part availability, and make the system reliably expandable again.
Maximise flexibility
PLC change
Reduce your effort
Electrical components
The selection of electrical components has a direct impact on system availability, maintenance requirements, and spare-part costs. Especially in older production systems, a large number of different device types and manufacturers often results in unnecessary complexity and excessive spare-part inventories.
Vimotech supports the cross-manufacturer analysis and standardization of electrical components. We consider technical compatibility, availability, long-term support, and future expandability.
Where appropriate, we reduce the number of different component types through targeted standardization or moderate oversizing. At the same time, the deliberate use of several suitable manufacturers can help reduce dependencies and improve long-term availability.
Older control systems and machines often provide only limited capabilities for data storage, batch tracking, and process documentation. Missing interfaces or limited computing power can also make it difficult to connect them to modern databases, control systems, or higher-level production systems.
As part of a modernization, relevant machine and process data can be captured selectively, stored in a structured manner, and made available for analysis. This creates better opportunities for traceability, quality documentation, fault analysis, and process optimization.
If direct access to the existing control system is not practical or technically feasible, the required signals can also be captured using additional sensors or external data acquisition systems and archived independently of the legacy control system.
Knowledge is power
Documentation and charge tracking
Safety first
Safety technology
In older production systems, safety functions are often implemented using numerous individual relays, contactors, and hardwired circuits. This makes modifications, diagnostics, and troubleshooting more difficult and can make extensions unnecessarily complex.
As part of a modernization, existing safety functions can be assessed and selectively transferred to current safety controllers and modern protective systems. This allows functions to be implemented more flexibly while providing a clearer overview of safety-related conditions.
Modern solutions using safety PLCs, light curtains, safety scanners, or safety mats can also help make interventions in the process more efficient without compromising the required level of safety.
Improved diagnostics and visualization of safety-related conditions help identify the causes of downtime more quickly and avoid unnecessarily long production interruptions.
The Vimotech concept for success
Measuring & testing technology taken further
Robustness and durability as well as flexibility and adaptability
The devices must be able to withstand the demanding conditions in industrial environments, such as high temperatures, humidity, vibrations and chemical influences. Furthermore, the technology should be easy to integrate into different applications and systems and be able to adapt to changing requirements.
Data acquisition and analysis
In addition to the acquisition of measurement data, the analysis and interpretation of this data is also of crucial importance. Advanced analysis tools can help to detect patterns, identify anomalies and reveal optimization potential.
Conformity and certification - integration of Industry 4.0 technologies
Especially in regulated industries such as the steel and aluminum industry, it is important that the measurement technology complies with the applicable norms and standards and possibly has certifications such as ISO 9001 or NADCAP approvals. The integration of Industry 4.0 technologies such as IoT (Internet of Things), artificial intelligence and machine learning enables even more intelligent and predictive use of measurement and testing technology in automation.