Industrial Control Upgrades & Retrofits
Breathe new life into old machines
Concept Systems specializes in industrial control upgrades that modernize legacy systems for plant managers and maintenance engineers facing outdated PLCs, HMIs, and motion controls. Our retrofits deliver enhanced safety, efficiency, and scalability without the expense of full equipment replacement, extending the life of your machinery in industries like aerospace and food & beverage.
How Our Industrial Control Retrofits Deliver Modern Performance
We assess your existing control systems, identify upgrade opportunities, and execute targeted retrofits using proven Rockwell technologies to align with current production demands. This approach transforms aging machinery into reliable assets that meet modern safety standards and operational speeds.
In environments with tight budgets and high uptime requirements, these equipment retrofits prevent costly breakdowns, reduce energy waste, and prepare your facility for future expansions—without the disruption of complete overhauls.
Key Benefits You Gain From Our Control System Retrofits
- Extend equipment life by 10–15 years through targeted retrofits
- Reduce operational costs with energy-efficient components like PowerFlex drives
- Enhance safety compliance using GuardLogix safety-rated systems
- Boost production throughput by modernizing to ControlLogix PLCs
- Minimize downtime with phased implementation and minimal facility disruption
- Improve data visibility and diagnostics via FactoryTalk View HMIs
- Achieve faster ROI compared to buying new machinery
- Scale easily for growing demands in high-volume manufacturing
What Concept Systems Delivers in
Every Industrial Control Retrofit Project
Assessment & Planning
- Detailed analysis for factory-wide control system retrofits
- Site audits of legacy PLCs, HMIs, and motion systems
- Compatibility analysis for upgrades like PLC5 to ControlLogix
- Cost-benefit modeling and risk assessments for retrofit feasibility
Technical & Engineering Services
- Custom PLC programming and HMI development (FactoryTalk View/Optix)
- Motion control integration with Kinetix servo drives
- CNC machine retrofits using FANUC, Rockwell PNC, or Siemens controls
- Safety system enhancements with GuardLogix
Integration & Deployment
- Minimal facility disruption planning for large-scale factory retrofits
- Panel fabrication in our in-house UL-508A shop
- Factory and site acceptance testing (FAT/SAT)
- Phased rollout to maintain production continuity
- Third-party equipment compatibility testing
Documentation & Training
- As-built drawings and system manuals
- Operator and maintenance training sessions
- Ongoing support plans for post-upgrade optimization
Industries We Regularly Serve With Factory & Equipment Retrofits
- Aerospace
- Food & Beverage
- Warehousing & Logistics
- Building Materials
- Mining & Metals
- General Discrete and Process Manufacturing
Common Industrial Control System Retrofit Projects We Execute
- Legacy PLC5 to ControlLogix migrations for improved reliability
- HMI panel refreshes with FactoryTalk Optix for intuitive interfaces
- Multi-axis motion control retrofits for precision applications
- Full plant-floor control system harmonization
- Safety upgrades to meet OSHA and industry standards
- Energy-efficient drive installations (PowerFlex VFDs)
- CNC machine modernizations for faster cycle times
Why Manufacturers Choose Concept Systems for Control System Retrofits
As a 25-year Rockwell Automation Solutions Partner and CSIA-certified integrator, we leverage principal engineers with decades of retrofit experience to ensure seamless transitions. Our in-house panel shop and consistent project methodology mean upgrades are delivered on time, with transparent communication and no hidden costs.
We go beyond the install: from initial assessment to lifetime support, our vendor-agnostic approach guarantees the right fit for your systems, whether Rockwell or compatible alternatives.
Automation Consulting
Looking to learn a little more?
Read how we helped one of the world’s leading frozen potato suppliers create a new process control standard and streamline it across more than a dozen locations.
Get Started With Industrial Control Retrofits
Ready to modernize your controls without the full cost of new equipment?
Contact Concept Systems for a free assessment and see how a targeted retrofit can transform your operations.
Frequently Asked Questions About Industrial Control Upgrades
What types of legacy systems do you upgrade?
We specialize in PLC5, older HMIs, and outdated motion/CNC controls, migrating to modern equivalents like ControlLogix and FactoryTalk View.
How long does a typical control system retrofit take?
Most projects span 3–6 months, depending on scope, with minimal downtime through off-site panel builds and phased testing.
Can you retrofit without replacing the entire machine?
Yes—our targeted upgrades focus on controls only, preserving mechanical components while enhancing performance and safety.
Do you support non-Rockwell technologies?
While Rockwell is our core expertise, we integrate with FANUC CNC, Siemens, and other platforms for hybrid retrofits.
What safety standards do your upgrades meet?
All retrofits incorporate GuardLogix for SIL 3 compliance, aligning with OSHA, NADCAP, and industry-specific requirements.
Is there an initial assessment fee?
Your first site audit and upgrade proposal are complimentary to help you evaluate options risk-free.