The machinery may still be mechanically sound, but its electronics, control systems, or safety features have become obsolete, and replacing it is not always the best decision. Industrial machinery retrofit makes it possible to modernise your existing equipment, extend its service life, and adapt it to today’s production requirements without taking on the cost of a new machine.

At BAMA, we are specialists in industrial retrofit. We have a technical office with extensive experience in industrial automation, control engineering, and equipment upgrades for different industrial sectors.

Applications of retrofit in industrial machinery

Retrofit can be applied to virtually any type of industrial equipment that, while mechanically functional, requires an upgrade to its control systems, electronics, automation, or safety. At BAMA, we have delivered retrofitting projects across a wide range of sectors, working on machines ranging from complete production lines to individual high-precision equipment. These are some of the most common applications:

Throughout our track record, we have received countless requests for bespoke solutions for a wide variety of applications. While our core expertise is industrial, we have worked across many different sectors. The most notable include:

Retrofit of CNC machines and machining centres

  • Replacement of obsolete numerical controls with state-of-the-art CNC systems
  • Replacement of servomotors, spindles, and variable frequency drives

Retrofit of hydraulic and mechanical presses

  • Migration from hydraulic systems to servo-electric drives
  • Integration of safety systems in accordance with RD 1215/97

Retrofit of packaging, bottling, and end-of-line systems

  • Upgrade of PLCs, sensors, and SCADA supervision systems
  • Automation of case packing and palletising processes

Retrofit of electrical panels and control systems

  • Complete redesign of the panel with current components and technical documentation
  • Integration of HMI, industrial communications, and real-time monitoring

Our industrial machinery retrofit service

Our retrofit service covers every phase of the intervention, from the initial equipment diagnosis through commissioning and production validation.

For us, the most critical stages are the preliminary analysis and detailed engineering, as they determine whether the modernization addresses the machine’s real shortcomings without oversizing the investment. Every retrofit is unique, so we design solutions tailored to the condition of the equipment, the production process in which it operates, and the applicable regulations.

Your industrial machinery retrofit specialist: comprehensive, bespoke modernisation.

Diagnosis and technical assessment

The first step is to analyse the equipment’s actual condition: we review the mechanical, electrical, electronic, and safety aspects to identify which components are obsolete, which faults are recurring, and which improvements will have the greatest impact on performance and reliability. Based on this diagnosis, we produce a detailed technical report defining the scope of the retrofit.

Engineering and solution design

We design the intervention in collaboration with you, combining our technical knowledge with your experience of the equipment and the production process. This phase covers electrical, electronic, and control development and, when necessary, mechanical improvements. Everything is documented before execution.

Retrofit execution

We carry out the complete modernization of the equipment: component replacement, wiring, installation of new control systems, upgrading of electrical panels, installation of sensors, and PLC and HMI configuration. Each intervention is executed within the agreed downtime to minimize the impact on your production.

Commissioning and validation

Once the intervention is complete, we perform functional tests, parameter calibration, and validation in the real production cycle. The equipment is not handed over until it operates with the stability, precision, and safety defined in the project.

After-sales support and maintenance

Retrofit does not end with commissioning. We provide ongoing technical support and preventive maintenance to ensure that the modernised machinery maintains its performance over time, avoiding unplanned downtime.

Specialists in industrial machinery retrofit

At BAMA, we do not just modernise equipment: we design comprehensive retrofit solutions covering the mechanical, electrical, electronic, and automation aspects of each machine. Our experience in industrial engineering and machinery manufacturing enables us to understand the equipment from the inside, accurately diagnose what it needs, and execute the modernisation with guarantees that few retrofit providers can offer.

That combination of expertise in design, manufacturing, and industrial automation is what sets us apart: we do not adapt generic solutions; instead, each retrofitting project is custom-developed for the equipment, the production process, and your plant’s real objectives.

Industrial machinery retrofit tailored to your needs

If your machinery is still producing but is limited by obsolete electronics, lack of spare parts, or safety systems that no longer comply with regulations, machine retrofit is the most cost-effective alternative to full replacement. At BAMA, we are a retrofit company with experience in industrial automation, and we approach each project with technical solutions tailored to your equipment and your real production process.

Contact us for an initial, no-obligation assessment.

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Frequently Asked Questions About Industrial Machinery Retrofit

What is industrial machinery retrofit?
Industrial machinery retrofit consists of modernising or upgrading existing industrial equipment by replacing obsolete components—such as control systems, electronics, electrical panels, or safety elements—with current technology. Unlike buying a new machine, retrofit leverages the equipment’s original mechanical structure, which is often still functional, and renews only what limits its performance, safety, or availability.

What does retrofitting mean, and how is it different from a repair?
Retrofitting is the technical English term used in industry to refer to the retrofit process. Its meaning goes beyond a simple repair: while a repair returns the machine to its original condition, retrofitting transforms it by incorporating technology that did not exist when the equipment was manufactured. The result is a machine with capabilities superior to the original in terms of control, efficiency, safety, and connectivity.

What advantages does retrofitting offer compared to buying new machinery?
The main benefits of retrofit are a significantly lower investment than purchasing new equipment, shorter execution times, minimal disruption to the plant layout, and the ability to retain robust mechanics that, in many cases, are no longer manufactured to the same quality. In addition, retrofitting makes it possible to adapt the equipment to current regulations, improve energy efficiency, and reduce unplanned downtime due to lack of spare parts or recurring electronic failures.

How much does an industrial machinery retrofit cost?
The price of a retrofit depends on the type of machine, the scope of the intervention, and the systems that need to be upgraded. Migrating a numerical control on a machining centre is not the same as modernising a complete packaging line. As a general reference, a retrofit typically represents between 20% and 50% of the cost of an equivalent new piece of equipment, making it a highly competitive alternative. At BAMA, we carry out an initial, no-obligation technical assessment to define the scope and budget for each project.

How is retrofit related to Industry 4.0?
Retrofit 4.0 is one of the most efficient ways for plants with earlier-generation machinery to access the benefits of Industry 4.0 without renewing their entire installed base. Through retrofitting focused on digitalisation, IoT sensors, real-time monitoring systems, connectivity with SCADA or MES platforms, and data collection capabilities for predictive maintenance are incorporated. The equipment moves from operating in isolation to being integrated into the plant’s digital ecosystem.

Does retrofit include compliance with RD 1215/97?
Yes. One of the most common reasons for carrying out a retrofit is precisely to bring industrial machinery into compliance with current safety regulations, especially Royal Decree 1215/97 on work equipment. The process includes risk assessment, the incorporation of protective systems, interlocks, and emergency stops, and the generation of the technical documentation that certifies the equipment’s regulatory compliance once modernised.

How do I know if my machine is a candidate for retrofit?
A machine is a good candidate for retrofit when its mechanical structure is still in good condition but it has limitations in its electronics, control, automation, or safety. The clearest signs are: difficulty finding spare parts, frequent stoppages due to electronic faults, inability to integrate the equipment with modern systems, or non-compliance with current safety regulations. If the mechanical base is compromised, the investment may not be worthwhile and it may be preferable to consider new equipment.