At Liebherr, “reman” stands for “remanufacturing”, the complete reprocessing of a machine to the standard of a new one. This is also the goal of retrofitting, which involves upgrading a machine with new technology and components. The reprocessing of existing machinery is a topic being explored at EMO 2025. In addition to automation, artificial intelligence and digitization, sustainability is one of the three key topics under the spotlight at the world’s leading trade fair for production technology, with sustainable production now long considered a key competitive factor.
Retrofitting pays off, in more ways than one
Retrofitting is far more than simply the inexpensive alternative to a new purchase. Instead, it represents a strategic investment, particularly in the sustainability of those companies from the machine tool industry currently under pressure from the current economic climate and thus more cautious when it comes to investment. Instead of acquiring brand new machinery, key components such as CNC controls, drives, sensors or Industry 4.0-capable interfaces are updated. Precision, process stability and productivity are increased, while access is provided to digital services such as condition monitoring or networked production control.
Retrofitting also pays off in terms of energy efficiency and sustainability: consumption values are drastically reduced through the replacement of old drives and motors, which in turn lowers both operating costs and carbon emissions. At the same time, valuable resources are spared as the existing machinery remains in use and is not replaced by entirely new models. The machinery is also adapted to current safety standards and machine directives, not only meeting legal requirements but improving employee safety standards too.
In economic terms, retrofitting brings several benefits for companies. According to Glatzeder, depending on the situation, investment costs can be reduced by at least a third compared to a new acquisition, sometimes significantly more. There are far less downtimes due to the generally shorter retrofitting phase, while the payback period is noticeably curtailed. In a time of global supply chain issues and economic uncertainties, retrofitting also allows for greater planning security.
Retrofitting thus combines enhanced technical performance with economic reason, along with environmental responsibility and a clear contribution to sustainability. It is a tool used by companies to improve their competitiveness even in difficult times and to set the course for a sustainable production. With this in mind, it is not hard to see why retrofitting is a key topic for quite a few visitors and exhibitors attending EMO.
Liebherr-Verzahntechnik: Used machinery as good as new
This also applies to Liebherr-Verzahntechnik, manufacturer of machine tools and automation solutions for the cost-efficient production of gears. The major international appeal of EMO makes this a key calendar event for the globally active company. “This is where we connect with all our important partners,” explains Glatzeder. “The broad spectrum of visitors, representing companies of all sizes, is a very appealing aspect when it comes to retrofitting.”
Customers with older Liebherr-Verzahntechnik machinery have a number of options. Outdated machines still performing well can be generally overhauled or repaired. With a general overhaul, the reman experts clean, calibrate and rework all the basic components. All wear parts, seals, drives and motors are replaced and only the machine casting and housing remain unchanged, however are optically refined. Another option is to purchase reconditioned used machinery. “Whereby ‘used’ is technically quite misleading,” adds Glatzeder. “The machinery that leaves our factory from the reman program represents state-of-the-art manufacturer quality and comes with a new warranty.” Remanufacturing carried out by Liebherr-Verzahntechnik always aims for the state-of-the-art and takes the latest innovative approaches into consideration. In this respect, machinery averaging 20 to 25 years of service is practically on par with the standard of new machinery following its reconditioning and renewal.
Kapp Niles: Retrofitting providing a second chance – more productive and sustainable
For EMO exhibitor Kapp Niles from Coburg, provider of machine tools and solutions for the fine machining of gears and profiles, the modernization of several machine series is also part of the company’s portfolio. As every grinding machine is subject to operational wear, the aim is to avoid the failure of critical components and, in extreme cases, the standstill of the entire grinding machine. Kapp Niles offers two solutions here. The “KN Recontrol” involves a complete control upgrade, while the “KN Retrofit” also includes a full mechanical overhaul.
“A Kapp Niles machine retrofit offers both an economic and resource-saving alternative to a new acquisition,” confirms Andreas Paatz, Head of Service/Tools/Digitization at Kapp Niles. At the same time, the renewal of components ensures the availability of spare parts. And, he continues, the machines are prepared for the collection of process and machine data to Industry 4.0 standards. The crucial advantage of receiving upgraded machinery directly from Kapp Niles and not a third-party provider lies in the dovetailing of software and mechanical engineering. New developments are incorporated from current machine series, equipment and functions expanded, machine documentation updated, and downtimes kept to a minimum during the modernization process.
Customers receive machinery that not only boasts state-of-the-art technology, but also long-term efficiency. “And the circular economy is supported through the extension of machine service life and component reuse,” adds Paatz. “This contributes to a sustainable economic approach that counts on recycling and resource conservation.”
Waldrich Coburg has long championed retrofitting
Waldrich Coburg has successfully championed retrofitting solutions for decades now, which represent around 10 percent of its revenue. “This approach is a key element of our service operations,” explains Dr. Tobias Abeln, CTO at Waldrich Coburg. The machines are already practically wear- free thanks to the hydrostatic guideways and predestined for a lifetime of several decades. In this respect, it is the ideal basis for a further extension of service life.
Through automation, control modernization and greater dynamic efficiency, the company is managing to increase the efficiency of its old machinery with retrofitting measures. It has also been successful in expanding functionality and flexibility through the implementation of new processing technologies such as turning, gear-cutting or HSC milling. Retrofitting has also contributed to quality improvements, improved operability and greater safety. At the same time, energy-savings and lower maintenance requirements, as well as shorter processing and downtimes are improving cost efficiency. Retention of the location, foundation and core components has also considerably reduced both investment costs and carbon footprint.
“This means that machines already more than 20 years in service remain economically viable,” confirms Abeln. “This is our way of supporting customers in their efforts to establish sustainable production processes.” EMO 2025 provides a superb platform for presenting the strategic benefits of such retrofitting solutions and innovative approaches to a wider audience.
From the repair solution to the strategic success model
Though the latest technologies and innovations may be the focus of EMO Hannover, retrofitting is also a key interest for many exhibitors and trade visitors. It has long represented more than simply the overhaul of existing facilities. It is a way in which to upgrade machinery to a technological level on par with new models – and involving considerably lower investment. Companies are strengthening their competitiveness as a result, without passing up the opportunity to benefit from state-of-the-art technology. This, and the environmental benefits it brings, are clear advantages for retrofitting.
