Machine modernisation
Machine modernisation is the process of upgrading existing equipment with the aim of improving performance, safety, and functionality, while ensuring compliance with current technical and legal standards. In practice, this may involve the replacement, rebuilding, or modification of mechanical and electrical components, control systems, or the integration of new technologies.
With many years of experience, Bros Control carries out machine modernisations in a comprehensive and reliable manner, consistently achieving the intended objectives and adapting equipment to meet the demands of modern production environments.
Main objectives of modernisation:
- Performance improvement:
- Increased operating speed,
- Reduced operational costs.
- Enhanced safety:
- Installation of guards, sensors, and emergency stop systems.
- Regulatory compliance:
- Adapting machines to meet current EU directives and local regulations.
- Expanded functionality:
- Adding new modules, tools, or software functions,
- Enabling product changeovers.
- Extended machine lifespan:
- Upgrading wear-prone components and strengthening structures.
All modernisation works are carried out in accordance with the EU Machinery Directive 2006/42/EC, current safety standards, and the client’s internal health and safety procedures.
Scope of services:
Mechanical modernisation:
- Replacement of worn components (bearings, shafts, gearboxes),
- Structural modifications (e.g. reinforcements, geometry changes),
- Use of new materials and processing technologies (heat treatment, surface treatment, composites).
Electronics and control systems:
- Replacement of outdated PLCs with modern controllers,
- Installation of vision systems and measuring sensors,
- Modernisation of operator panels (HMI),
- Replacement of operator interface and protective switching components,
- Replacement of control cabinets.
Software:
- Update and optimisation of control programs,
- Implementation of Industry 4.0 functionalities (real-time monitoring and data analysis).
Energy efficiency:
- Installation of energy-efficient drives,
- Use of frequency converters for speed regulation.
Automation and robotics:
- Integration of industrial robots and collaborative robots (cobots),
- Addition of automatic feeders and conveyors,
- Full integration with existing production lines.
Thanks to modern technologies, machine modernisation not only increases efficiency and safety but also reduces operational costs, shortens downtime, and minimises environmental impact. The Bros Control team will gladly prepare an analysis and propose a modernisation concept tailored to your specific requirements.
