ICA — Retrofit of industrial equipment
Upgrade
rather than
replace
Modernise your existing machines and lines to improve performance, safety and sustainability, while reducing costs and environmental impact
Industrial equipment represents a significant capital investment, but technology advances faster than mechanical components wear out. Retrofit services enable you to modernise control systems, improve safety, optimise performance and add new features to existing machinery—at a fraction of the cost of replacement.
Our retrofit expertise covers mechanical improvements, replacement of electrical systems, modernisation of automation and safety compliance updates. We replace obsolete controllers, outdated cabinets and discontinued components with current technologies while preserving the mechanical integrity of your equipment and the operational know-how of your teams.
Whether it’s due to component obsolescence, efficiency improvements, compliance with new safety standards or the addition of Industry 4.0 connectivity, retrofitting offers a practical solution. The result: extended service life, improved performance, regulatory compliance and uninterrupted production—all without the disruption and cost of a complete replacement.
Our expertise
Upgrade your equipment without replacing it
Mechanical retrofit
Replacement of worn components, upgrading of actuators, improvement of precision and optimisation of mechanical performance. We modernise drive systems, bearings, guides and transmission elements to restore or exceed original specifications while maintaining compatibility with existing structures.
Electrical retrofit and automation
Replacement of obsolete controllers, updating of electrical cabinets, modernisation of HMIs and integration of Industry 4.0 connectivity. We carry out migration from discontinued systems to current technological platforms while preserving your operational know-how and minimising production interruptions.
Compliance
Bringing old equipment up to current safety standards. Adding safety barriers, emergency stops, interlocking systems, and protective devices in accordance with the Machinery Directive. Includes a comprehensive risk analysis, safety system design, and technical file for CE marking.
Performance optimisation
Increased throughput, reduced cycle times, improved quality and lower energy consumption. We analyse your current performance, identify bottlenecks and implement targeted improvements—such as faster actuators and smart controls—to deliver measurable gains in productivity and efficiency.
why retrofit rather than replace
Get the most out of your existing equipment
Substantial savings
Retrofitting typically costs 30 to 60% less than purchasing new equipment. Retain your mechanical structures, foundations, and existing installations by only modernising what is necessary. Avoid hidden costs of new equipment: site preparation, retraining operators, reconfiguring lines, and long commissioning periods.
Quick return to production
Retrofit projects are completed in weeks rather than months. There is no need to wait for new equipment to be manufactured—which usually takes 6 to 12 months. Planned downtime is measured in days, not weeks. Your operators are already familiar with the machine, reducing training time and maintaining productivity from the very first day the modernised system is up and running.
Preserve your expertise
Retain years of process know-how, operator skills, and optimised settings. The layout, workflow, and operational logic remain familiar. No disruption to proven production methods, just enhanced capabilities. Your team continues to work with equipment they are familiar with, reducing errors and maintaining quality during the transition.
Sustainable solution
Reduce industrial waste by extending the lifespan of equipment rather than discarding machines that are still in working order. Reduce your carbon footprint—manufacturing new equipment requires significant amounts of energy and resources. Demonstrate your environmental responsibility to your customers and stakeholders whilst achieving operational improvements and cost savings.
From assessment to commissioning: our proven methodology
Structured approach to
minimise downtime
1
Assessment
On-site inspection and documentation of the current state, identification of obsolete components, performance measurement, and problem diagnosis.
2
Proposal
Detailed specification of the retrofit with cost breakdown, ROI calculation, planned downtime and project schedule with clear milestones.
3
Engineering
Detailed design, procurement of components, development of programmes and pre-assembly/testing in the workshop before on-site installation.
4
Installation
Planned shutdown, systematic replacement of components, system integration, electrical wiring and mechanical assembly with minimal disruption.
5
Commissioning
System testing, performance validation, operator training on new features, delivery of complete documentation and ongoing technical support.
The ica approach
We prioritise an approach based on eco-design and process optimisation. By modernising existing systems, we reduce our environmental footprint whilst improving reliability, safety and productivity, in line with a philosophy of continuous improvement (ISO 9001).
Extending the lifespan of industrial equipment while optimising costs, performance and environmental impact? That's our philosophy.
Need tailored support?
Our experts are here to guide you every step of the way.