Future-Proofing Your Existing Machines
Extend the lifespan of your existing machinery and prepare it for Industry 4.0. MSG Solutions modernizes mechanics and control systems while integrating high-precision inline measurement technology. Achieve seamless quality monitoring and digital twins directly within your production line – efficiently and cost-effectively.
What Does Modernization & Retrofit Mean in Mechanical Engineering?
Retrofit: Targeted Upgrades to Existing Technology
Retrofit refers to the targeted upgrading of existing machines and systems with modern technology. Unlike new purchases, the proven basic construction is preserved – only the components that no longer meet current requirements are replaced or supplemented. Typical retrofit measures include: replacing outdated PLC controls (e.g., Siemens S5 to S7 or TIA Portal), converting from hydraulic to servo-electric drives, integrating sensors for predictive maintenance, and retrofitting interfaces for MES and ERP connectivity.
When Is Modernization Worthwhile?
Modernization is particularly worthwhile when spare parts for existing controls are no longer available, productivity falls behind current market demands, energy costs rise due to outdated drive technology, integration with Industry 4.0 systems is desired, or quality requirements demand integrated measurement technology. In many cases, a retrofit pays for itself within 12–24 months – at 40–70% lower investment costs compared to a new system.
MSG Solutions Modernization Services at a Glance
Control and Drive Modernization
We replace outdated PLC controls, frequency converters, and drive systems with current components from leading manufacturers. The advantage: higher cycle times, lower energy consumption, and full spare parts availability for the coming decades. MSG Solutions handles complete electrical engineering, control cabinet construction, programming, and commissioning – from a single source.
Mechanical Overhaul and Expansion
In addition to control technology, we also modernize the mechanical components of your systems: replacement of worn guides and bearings, expansion with additional processing stations, optimization of material flow and tool changes, and integration of robotics for automated loading and unloading.
Integration of Measurement Technology & Digital Twin
What sets MSG Solutions apart from other modernization providers: we integrate our own, industrially proven measurement technology directly into your modernized system. Our systems such as TWINEX ScanEnd, TWINEX ScanOut, TWINEX ScanIn, TWINEX Shade, TWINEX SurfOut capture geometry and surface data inline and in real time. The result: a digital twin of your production that enables 100% quality monitoring, reduces scrap, and allows data-driven process optimization – directly from the first produced part.
Industry 4.0 Integration and Data Connectivity
Modern production requires seamless data flows. MSG Solutions equips your existing systems with IoT sensors, OPC-UA interfaces, and dashboard solutions. This gives you real-time insight into machine performance, energy consumption, and quality metrics – the foundation for predictive maintenance and continuous improvement.
Why MSG Solutions for Your Modernization?
Mechanical Engineering and Measurement Technology from a Single Source
Most modernization providers deliver either mechanical engineering or measurement technology. MSG Solutions combines both: we know your system from mechanics to software and complement it with precise inline measurement technology. This creates an end-to-end solution that optimizes production efficiency and quality assurance in one step.
Over 25 Years of Industry Experience
Since 1998, MSG Solutions has been developing individual mechanical engineering and measurement technology solutions at its location in Schmallenberg, Sauerland. Our engineers and technicians have successfully completed hundreds of modernization projects in steel and pipe production, automotive industry, construction supply, and other industries – worldwide.
Minimal Downtime, Maximum Planning Reliability
We know that every hour of production downtime counts. That's why we plan modernizations so that the maximum share of work takes place in advance – control cabinets are pre-wired, software is simulated and tested, mechanical assemblies are pre-assembled. The on-site conversion then takes place in a coordinated, time-optimized window.
Sustainability Through Retrofit
Modernization is not only economically but also ecologically sensible: by reusing the base machine, resources and CO₂ are saved. Modern drives reduce energy consumption by up to 30%, and optimized process control reduces material waste and scrap.
Frequently Asked Questions About Modernization & Retrofit (FAQ)
What is the difference between modernization and retrofit?
In general usage, the terms are often used synonymously. Technically, retrofit refers to the targeted upgrading of individual components (e.g., new control system), while modernization describes a more comprehensive approach that can also include mechanical overhaul, safety adaptations, and process optimization. MSG Solutions offers both – tailored to your needs.
For which machines and industries does MSG Solutions offer modernizations?
We modernize production systems in steel and pipe production, the automotive industry, construction supply, and general mechanical engineering. Typical systems include sawing lines, straightening machines, bending systems, inspection lines, handling systems, and special machines.
How does a modernization project at MSG Solutions work?
In four phases: 1) Analysis & assessment of your system, 2) Concept development with cost-benefit evaluation, 3) Implementation with maximum pre-fabrication to minimize downtime, 4) Commissioning, training, and ongoing service.
Can MSG Solutions also integrate measurement technology into existing systems?
Yes, this is one of our core competencies. We integrate our measuring systems (TWINEX ScanEnd, TWINEX ScanOut, TWINEX ScanIn, TWINEX Shade, TWINEX SurfOut) into existing and modernized systems. This gives you a digital twin of your production with 100% inline quality monitoring.
How long does a modernization take and what are the costs?
Duration varies depending on scope: smaller control modernizations can be completed in a few weeks, comprehensive system modernizations require 3–6 months including planning. Costs are typically 40–70% of a new purchase – with a payback period of 12–24 months.
Which Industry 4.0 technologies does MSG Solutions integrate?
We equip your systems with OPC-UA interfaces, IoT sensors, real-time dashboards, MES/ERP connectivity, and predictive maintenance. Combined with our inline measurement technology, this creates a fully connected, data-driven production.
Will my system be down during modernization?
We minimize downtime through maximum pre-fabrication: control cabinets, software, and mechanical assemblies are completely prepared and tested in advance. This makes the actual on-site conversion significantly shorter than conventional approaches.
Does MSG Solutions also offer service after modernization?
Yes, we offer comprehensive after-sales services: maintenance contracts, remote maintenance via VPN, spare parts supply, training, and short-notice on-site deployment. Our goal is to keep the availability of your system at the highest level long-term.
Is modernization more sustainable than a new purchase?
In most cases, yes. By reusing the base machine, significant amounts of material, energy, and CO₂ are saved. Additionally, modern drives reduce energy consumption by up to 30%, and more precise process control reduces material waste.