October 15, 2025

Digital retrofit: old machines, new opportunities

How companies can upgrade their existing systems to meet the requirements of Industry 4.0, increase efficiency and save costs.
Retrofit of an existing plant
In many manufacturing companies, there is a gap between existing machines and the requirements of Industry 4.0.
Often, machines do not provide the required data for Predictive maintenance or process optimizations.
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At the same time, complete new purchases are expensive, time-consuming and sometimes even associated with production downtime.
This is exactly where retrofitting comes in. Existing machines are specifically retrofitted with modern hardware and software. This allows to improve performance and meet the requirements of digital production.
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But what does digital retrofit actually mean in practice? And what steps are necessary to turn an old machine into a networked, data-supported production tool?

Content

Retrofitting Definition
New purchase vs. retrofit
Digital retrofit process
The right hardware for a retrofit
Retrofit case study
Benefits of Retrofit
Conclusion

Definition Retrofitting

Retrofitting refers to the modernization of existing machines through the use of new hardware and software. Older systems are being technically upgraded to extend their lifespan, increase productivity and integrate digital functionalities retrospectively.

Digital retrofit

Digital retrofit is the targeted networking and digitization of existing machines in order to make them compatible with modern IT and data systems. The aim is to integrate existing systems into the digital world without replacing them.
For companies, retrofitting means much more than a technical upgrade. It is a strategic approach to make existing machines economical and future-proof.

Companies benefit in several ways:
Save costs by avoiding expensive new purchases
Increase efficiency by monitoring and optimizing machines based on data
Digitize production processes by connecting machines to IT and analysis systems
Predictive maintenance, through real-time digital monitoring
Increase flexibility by quickly adapting machines to new requirements
A digital retrofit transforms existing machines into networked, intelligent production tools without replacing the entire system.
Companies can protect their investments and extend machine running time while consistently entering the world of Industry 4.0.

New purchase vs. retrofit: When is a digital retrofit worthwhile?

Many companies face the question: Should a machine be replaced or retrofitted?
A complete new purchase is expensive, involves long downtimes and often requires large investments. A digital retrofit offers an attractive alternative. Especially when the mechanical base of the machine is still intact.
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A retrofit is worthwhile for your company if:
1. The machine works mechanically reliably, but digital functions are missing
2. Only control, data collection or networking need to be retrofitted
3. Rapid and cost-effective integration into digital production processes is required

How does a digital retrofit work?

A digital retrofit is carried out in two phases:

1. Technical retrofitting and networking of machines
2. Intelligent data evaluation and monitoring.

Step by step, a digitally networked and AI-supported production environment is created.
1

Connectivity of the machine

Digital retrofitting involves connecting existing machines to a digital system. Operating and status data is securely transmitted via IoT gateways and protocols such as OPC UA or MQTT, without interfering with machine control. This creates the basis for networked and data-based production.
2

If necessary, retrofitting of required sensors

Not all machines have the sensors required for reliable condition monitoring. Therefore, additional sensors are often installed as part of a digital retrofit. The retrofit thus creates the data basis for subsequent monitoring and analysis.
3

Data collection

After networking, continuous Capture and transfer of machine data. A gateway collects and filters data before it is sent to a local platform or cloud. This creates a high-quality data basis for analyses.
4

Data evaluation

In the data evaluation phase, the collected information is analyzed and interpreted. Machine learning algorithms identify patterns and trends in measurement values.
5

Derivation of measures

Based on the gained knowledge, concrete measures can be derived. Critical alerts prompt immediate action. Less urgent recommendations are incorporated into maintenance plans. The system is constantly learning and increases efficiency permanently.

The right hardware for a retrofit

Modern hardware is used to connect and collect data from your machines: An IIoT gateway or embedded computer collects data from sensors, preprocesses it, and reliably transmits the data to the cloud or local dashboard. Thus, the hardware forms the central interface between the machine and digital monitoring.

At this point, our collaboration with KSB becomes essential.
KSB has more than 150 years of experience in pump construction, aiomatic has many years of expertise in data science and artificial intelligence. Together we have developed a tailor-made package that combines smart software and sensors for fully automatic monitoring of vibrations and temperature of rotating machines.
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The sensor installation is simple and efficient:
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The sensors are simply attached to the relevant measurement points, for example on the bearing support, with 2-component adhesive.
Up to 30 sensors can be connected to the gateway at the push of a button (range approx. 25 m).
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All installation locations and machine details are sent to aiomatic via form.
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Learn more
Dashboard Retrofit and Predict Package

Digital retrofit at Hansaport

At Hansaport, Germany's largest bulk cargo port, existing conveyor belts were digitally upgraded with the Retrofit & Predict package.
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The objective is to monitor the condition of critical drive components in real time and prevent failures.

The first step was to retrofit sensors directly at the engine, transmission and bearing block.
The sensors were connected to the aiomatic platform via an IIoT gateway.
Roboter überwacht die Maschinen von morgen
After successful networking, data collection and analysis began: aiomatic's AI models identify anomalies at an early stage and send anomaly alerts.
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In this way, the digital retrofit transforms existing systems into intelligent, self-monitoring systems, without modifications or long downtimes.
The result: higher plant availability, predictable maintenance and significant cost savings.

Benefits of Retrofit

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Cost effective

Existing machines are upgraded and do not have to be replaced at a high cost.
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Quick installation

Sensors and IIoT gateway are ready for use without long downtimes or modifications.
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Real time monitoring

Continuous status monitoring of all critical components via dashboard.
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Predictive maintenance

Early detection of anomalies prevents failures and reduces repair costs.
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Sustainable

Extends the life of existing machines and reduces resource consumption.
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Future-proof

AI models learn with every data collection and continuously increase diagnostic accuracy.

Conclusion

Digital retrofit is much more than a technical upgrade.
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It is a strategic investment in efficiency, data usage and sustainability. Companies can modernize their machines without relying on new purchases.

With an experienced partner like KSB & aiomatic, the retrofit is a full-fledged step towards Industry 4.0.

This includes predictive maintenance, real-time data analysis, and proactive measures.
Employee of aiomatic in a machine room

Any further questions?

Our mechanical engineer Joel is happy to help you!
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