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A retrofit is not a repair. It is a targeted modernisation – and in many cases the more economical, more sustainable decision compared to a new purchase.
Modernisation Without Starting Over
A retrofit renews or upgrades individual components without replacing the entire machine. The result is a machine at the current state of the art – on a foundation that has proven itself over years.
Typical measures in a Heesemann retrofit:
- New controls at the current state of the art
- Replacement of worn or outdated drives
- Extension with new aggregate options
- Integration into modern production environments
- Increased motor power for higher capacity requirements
Making the Right Trade-Off
A new purchase makes sense when the fundamental machine architecture no longer fits the requirements. When an operation shifts from single-shift to three-shift running with a multiple of the output volume, a retrofit is no longer appropriate.
In all other cases – when the base machine is sound, requirements have changed only moderately, and the machine has been running reliably – the trade-off is worth examining:
- Retrofit costs versus new purchase costs
- Time required for training and changeover
- Loss of accumulated operator knowledge
- Sustainability: an overhauled machine avoids the resource cost of manufacturing a new one
In many cases the retrofit is the more economical decision. Not because Heesemann has no interest in new sales, but because honest advice takes that into account.
Pascal Diller, Head of Engineering, HeesemannWaiting Is More Expensive Than Acting
Heesemann does not wait until a machine breaks down. Service proactively reaches out to customers with older machines and checks whether an overhaul makes sense. Not out of commercial self-interest, but because an overhaul at the right time is significantly cheaper than one after an unplanned failure.
Service technicians recognise signs that operating staff miss: sounds that develop over months and are therefore perceived as normal. Wear on components that has no consequences yet – but will. Settings that have drifted over time.
Acting Early Saves Costs
An overhaul at the right time costs significantly less than one after an unplanned breakdown – and protects against production downtime.
Request service →Fewer Resources, Same Performance
An overhauled machine is more sustainable than a new one. This applies to the resources that would go into manufacturing a replacement, as well as the energy associated with producing a complete new machine.
For operations pursuing sustainability targets, this is a concrete argument: a Heesemann machine that is replaced after 30 years instead of 15 consumes fewer resources over that period than two machines over the same timeframe.
FAQ: Retrofit and New Purchase
What is the difference between a retrofit and standard maintenance?
Maintenance keeps the machine at its current level and addresses wear. A retrofit goes further: it modernises the machine with new controls, stronger drives or extended functions – bringing it to a technical standard it did not have at delivery.
When does a retrofit make economic sense compared to a new purchase?
As a rule of thumb: if the machine's base architecture still fits the requirements and production demands have not fundamentally changed, a retrofit is often more economical. Heesemann analyses this concretely – without a predetermined recommendation.
How long does a retrofit at Heesemann take?
That depends on the scope. A controls upgrade or component replacement can be completed in a few days. More extensive rebuilds take longer. Heesemann plans the retrofit to minimise production downtime.
Can Heesemann modernise older machines from the 1990s?
Yes. Heesemann actively supports machines that have been in production for over 30 years. The basic mechanical construction of these machines is often so robust that modernising the controls and individual components makes economic sense.
