Modernise the controller instead of replacing the machine
Your machine is still mechanically in good shape, only the control technology is outdated and spare parts are becoming scarce. Regulations may force you to take the machine out of service. Replace the controller with retavi for a modern, software-based solution. The proven mechanics stay untouched. Your machine keeps running for many more years. Including modern data connectivity and interfaces to IT systems.
Your benefit
Controller replaced quickly and easily with an advanced software-based solution, without touching the proven mechanics
No more risk from a shortage of spare parts for outdated control technology
The machine keeps running reliably for many more years as a result
Your starting point
Controller check
In a workshop, we look at how a controller swap for a specific machine looks technically and economically, including a fixed-price effort estimate.
Arrange an initial consultationChallenges
Controller outdated, mechanics intact
A machine's mechanics often last for decades, while the control technology is long outdated.
Spare parts becoming scarce
Spare parts for older controllers are barely available or only at high prices. Discontinued control platforms are no longer maintained or developed further by the vendor.
Regulations force replacement
New regulations require replacing outdated technology. The machine may no longer be operated.
A new machine would be uneconomical
A complete replacement is out of proportion to the value of the still-functional mechanics.
Classic solution vs. retavi
| Aspect | Classic solution | With retavi |
|---|---|---|
| Machine condition | Mechanics intact, controller outdated | Mechanics stay, controller modernised |
| Spare parts | Scarce, expensive or discontinued | Standard IT hardware and software, widely available |
| Approach | Complete new machine | Controller swap, fast and simple |
| Service life | Ends with the controller | Many more years of economical operation |
How retavi solves it
Three steps from an outdated controller to a modern machine.
Analyse the controller
Assess which functions your existing controller handles and how sensors, actuators and the mechanics are attached to it.
Replace the controller
The old controller gives way to a software-based solution. Powerful retavi development tools make the process fast and simple.
Keep operating
The machine keeps running reliably for many more years on the new controller. Including modern data connectivity and interfaces to IT systems.
Systems & connectivity
Processing & controlDevices & systems
Examples
Secure exposed interfaces and modernise the control system step by step
Situation
An existing machine runs reliably but uses older control and communication components. Direct remote access and end-of-life software make it hard to secure, while new regulations such as the EU Machinery Regulation and the Cyber Resilience Act raise the requirements for cybersecurity.
With retavi
retavi is first deployed as a gateway between the existing machine and the production network, controlling data and access paths and providing diagnostic data. New functions can then be added step by step as C# modules, up to fully software-based control.
Benefit
The machine stays productive while the critical interfaces are secured first. Instead of a full replacement, you get a plannable modernisation path in clear stages.
Talk to us about your automation challenges.
