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.
In many manufacturing companies, there is a gap between existing machines and the requirements of digital Industry 4.0.
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Systems often do not provide the data required for Predictive maintenance or process optimizations.
At the same time, complete new purchases are expensive, time-consuming and, in the worst case, associated with production downtime.

Digital retrofitting is the perfect solution for this issue. Existing machines are specifically retrofitted with modern hardware and then connected with smart software.

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?
Digital retrofit of a machine

Content

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

Definition (Digitaler) Retrofit

(Digital) retrofit refers to the modernization of existing machines and systems. This involves upgrading older systems technically, mechanically or digitally in order to extend their lifespan, increase productivity and integrate new functions retrospectively. Retrofitting can include, for example, the replacement of worn components, the adjustment of control or regulation technology, the installation of sensors or the integration of digital analysis and monitoring solutions.

Digital retrofit

Retrofit, in the classic sense, refers to the mechanical or electrical modernization of existing systems.
The aim is to extend the service life, increase efficiency and ensure the availability of spare parts.

Typical measures include the installation of modern sensors or drives as well as modifications to increase energy efficiency. The focus is on hardware and control technology.

Digitaler Retrofit

Digital retrofit is the addition of digital technologies to existing systems in order to make them compatible with modern IT and data systems.

The aim is to integrate existing systems into the digital world.
Intelligent sensors, data collection and AI-based analyses provide full transparency about the system status and thus the basis for efficient, predictive maintenance, without expensive new purchases.

Typical measures include retrofitting IoT sensors for condition monitoring, connecting to cloud or edge platforms, and using artificial intelligence.
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The focus is on data, connectivity and AI.
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For companies, digital 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

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

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.
2

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.
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 notifications 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:
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, aiomatic's AI models identify anomalies at an early stage and send notifications.
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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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