New life for old machines

Reman at Liebherr stands for remanufacturing, a complete refurbishment of a machine to the level of a new machine. Retrofitting, in which an existing machine is upgraded with new technologies and components, also goes in this direction. The reconditioning of existing machines is also a topic that will play a role at EMO 2025 from September 22 to 26 in Hanover. Alongside automation, artificial intelligence and digitalization, sustainability is one of the three focus topics at the world's leading trade fair for production technology. After all, sustainable production has long since become a decisive competitive factor.

Retrofit pays off in several ways

Retrofitting is far more than just a cost-effective alternative to buying new. Rather, it is a strategic investment in the future viability of companies in the machine tool industry in particular, which are under pressure in the current challenging economic situation and therefore tend to be reluctant to invest. Instead of purchasing completely new machines, central components such as CNC controls, drives, sensors or Industry 4.0-capable interfaces can be modernized. This increases precision, process stability and productivity and opens up access to digital services such as condition monitoring or networked production control.

Retrofitting also pays off in terms of energy efficiency and sustainability: Replacing old drives and motors noticeably reduces consumption, thereby cutting both operating costs and CO₂ emissions. At the same time, valuable resources are conserved as existing machines continue to be used and do not have to be replaced with completely new systems. In addition, the adaptation to current safety standards and machine guidelines not only fulfills legal requirements, but also improves employee protection.

From an economic point of view, retrofitting provides companies with several advantages. According to Reman department head Glatzeder, depending on the situation, the investment for this remains significantly below the level of a new purchase, with a cost advantage of a good third or even more. In addition, downtimes can be significantly reduced thanks to the usually shorter retrofit phase, and the payback period is noticeably shorter. At a time of global supply chain problems and economic uncertainties, retrofitting also provides greater planning security.

Retrofit thus combines technical performance enhancement with economic rationality, ecological responsibility and a clear contribution to sustainability. It is an instrument that helps companies to secure their competitiveness even in difficult times and to set the course for sustainable production. Against this background, it is obvious that retrofitting is an important topic for many exhibitors and visitors at EMO.

Used machines like new

This also applies to Liebherr-Verzahntechnik, manufacturer of machine tools and automation solutions for the economical production of gears. For the globally positioned company, the EMO is of outstanding importance due to its high level of internationality. "We reach all the important contacts there," explains Glatzeder. "The broad spectrum of visitors, which is recruited from both large and many smaller companies, is particularly attractive for the topic of retrofitting."

Customers with older machines have various options at Liebherr-Verzahntechnik. They can have their ageing machine, which is still performing well, overhauled or repaired. During a comprehensive overhaul, the Reman specialists clean all basic components, measure and rework them. They replace all wearing parts, seals, drives and motors. Only the casting and the housing of the machine remain, but are optically refurbished. Another option is to purchase another used machine that has been refurbished to as-new condition. "Whereby the term 'used' is actually misleading," adds Glatzeder. "This is because the machines from our Reman range are always up to date in manufacturer quality on delivery and come with a new warranty." Liebherr-Verzahntechnik always focuses on the latest technological level and takes into account innovations that are now available. In this respect, the machines, which are on average 20 to 25 years old, are virtually on a par with new machines after refurbishment and renewal.

Retrofit as a double opportunity - more productive and more sustainable

For EMO exhibitor Kapp Niles from Coburg, a supplier of machine tools and solutions for the fine machining of gears and profiles, the modernization of several machine series is also part of its portfolio. As every grinding machine is subject to operational wear, the aim is to prevent the failure of critical components and, in extreme cases, the downtime of the entire grinding machine in good time. Kapp Niles offers two solutions for this. While "KN Recontrol" involves a full control upgrade, "KN Retrofit" also includes a complete mechanical overhaul.

"A Kapp Niles machine retrofit offers an economical and resource-saving alternative to a new purchase," confirms Andreas Paatz, Head of Service/Tools/Digitization at Kapp Niles. At the same time, the availability of spare parts is restored by renewing components. And the machines are prepared for the collection of process and machine data in line with Industry 4.0. The decisive advantage of a modernization carried out directly by Kapp Niles and not by a third-party provider lies in the close integration of mechanical engineering and software. Further developments from current machine series can be incorporated, equipment and functions expanded, machine documentation updated and downtimes during modernization reduced to a minimum.

This means that customers not only receive technically state-of-the-art machines, but also machines that are economically reliable in the long term. "And by extending the service life of machines and reusing components, the circular economy is strengthened," adds Paatz. "This contributes to a sustainable economy that focuses on recycling and resource conservation."

Waldrich Coburg has relied on retrofitting for many years

Waldrich Coburg has also been successfully offering retrofit solutions for decades, accounting for around 10 percent of its turnover. "For us, this area is a fundamental part of our service business," emphasizes Dr. Tobias Abeln, CTO at Waldrich Coburg. In any case, the machines are virtually wear-free thanks to hydrostatic guides and are predestined for a service life of several decades. In this respect, this is the ideal basis for a further extension of the service life.

With the retrofit measures, the company has increased the efficiency of the old machines through automation, control modernization and greater dynamics. In addition, the company was able to expand functionality and flexibility by implementing new machining technologies such as turning, gear cutting and HSC milling. Quality improvements, improved operability and greater safety were also achieved thanks to the retrofit. At the same time, cost efficiency is improved thanks to lower energy and maintenance costs as well as shorter machining and downtimes. By retaining the installation site and foundation as well as the core components, significantly lower investment costs and a considerably lower carbon footprint are also possible.

"This means that machines that have been in use for over 20 years remain economically competitive," emphasizes Abeln. "In this respect, we support our customers in setting up their production processes for the future in a sustainable way." EMO 2025 offers an excellent platform to present the strategic added value of such retrofit solutions and innovations to a broad specialist audience.

From repair solution to strategic success model

Even if the focus at EMO Hannover is on new technologies and innovations, retrofitting will be an important topic for some exhibitors and trade visitors. This is because it has long been about more than just repairing existing systems. It is a way of bringing machines up to a technological level that can compete with new systems - and at significantly lower investment costs. Companies are thus securing their competitiveness without having to forego the performance of state-of-the-art technologies. This and the associated ecological benefits are clear plus points for a retrofit.

Christian Mannigel, specialist journalist, Handeloh

EMO, Hall 3, Stand E42