Retrofits & Upgrades
Retrofits & Upgrades That Rebuild Performance.
Your flexible packaging machines are capital investments. Manufacturers build them to last decades. INGSOL’s Retrofit and Upgrade Engineering extends that investment. We modernise controls, rebuild electrical systems, and improve mechanical precision. Therefore, you avoid the cost, complexity and downtime of full machine replacement.
What We Do​
Retrofit & Upgrade Engineering for Flexible Packaging Machinery
Not all Retrofit and Upgrade Engineering work is the same. INGSOL scopes each Retrofit and Upgrade Engineering engagement around the real problem. For example, this might be an obsolete control system. It could also be a mechanical issue. Sometimes it involves an electrical safety risk. Often, it involves a combination of all three.
The winder is the final stage of production and one of the most critical areas for product quality. Poor tension control leads to uneven rolls, inconsistent winding, rejects and rework.
INGSOL delivers winder automation modernisation using multi-drive configurations, load cell monitoring, dancer roller systems and closed-loop tension control for centre winding, surface winding and gap winding applications.
Benefits
- Better roll quality
- Reduced rejection rates
- Lower operator dependency
- Consistent product quality
Speed synchronisation between machine sections directly impacts film quality and process stability. Legacy haul-off systems and inaccurate cage positioning contribute to wrinkling, width variation, breakages, and inconsistent output.
INGSOL implements haul-off system upgrades using AC, DC and servo-based synchronisation technologies. We modernise cage system upgrades with servo and stepper drives integrated through PLC-controlled positioning algorithms.
Benefits
- Stable bubble guidance
- Consistent film gauge
- Reduced defects and breakages
- Improved production efficiency
Many quality issues originate from poor cooling performance. Unstable bubble behaviour, inconsistent film clarity and gauge variation are often symptoms of inadequate airflow management.
INGSOL delivers cooling system retrofit solutions using Variable Frequency Drives on IBC blowers, OBC blowers and exhaust systems. Airflow is continuously adjusted based on process conditions ensuring uniform cooling throughout production.
Benefits
- Improved film clarity
- Better bubble stability
- Consistent product properties
- Lower energy consumption manufacturing
Problems at the extruder and die zone affect the entire production process. Startup scrap, unstable output, gauge variation and extended changeovers often originate from poor coordination between extrusion and downstream equipment.
Our extruder die zone upgrade solutions modernise critical control systems and improve synchronisation between the extruder, haul-off and associated equipment.
Benefits
- Reduced startup scrap
- Faster changeovers
- Improved process stability
- Consistent output quality
A modern machine requires a modern control system. Outdated PLCs increase troubleshooting time, create operator dependency and limit visibility into machine performance.
INGSOL provides PLC upgrade services, legacy PLC replacement and complete industrial control system upgrade projects across packaging and process plants. We implement modern PLCs, intuitive HMIs, remote support capability and scalable control architectures designed for future integration with digital systems.
Benefits
- Reduced downtime
- Real-time diagnostics
- Improved process visibility
- Faster issue resolution
- Smart manufacturing readiness
Drives determine how effectively every section of your machine works together.
Outdated or mismatched drives increase energy consumption, accelerate wear and reduce overall performance.
Our drive upgrade industrial solutions replace ageing drive systems with high-efficiency AC drives engineered for precision synchronisation and long-term reliability.
What You Gain
- Significant energy savings
- Smooth machine operation
- Reduced mechanical stress
- Extended equipment life
- Full machine synchronisation
Machine Types We Upgrade
INGSOL has direct Retrofit and Upgrade Engineering experience across major flexible packaging equipment. For example, this spans print and lamination through to extrusion and converting.
Blown Film Lines
winder, haul-off, cage, cooling, PLC and drive upgrades through our Retrofit and Upgrade Engineering process.
Printing Machines
register control, tension management and synchronisation improvements.
Lamination Machines
Bonding optimisation, PLC upgrades, and speed control.
Slitter
Rewind tension control, speed enhancement, and accuracy improvements.
How We Work
Our Retrofit Engineering Process
Our Retrofit and Upgrade Engineering process eliminates two things that kill retrofit projects. These are scope surprises and commissioning failures. Every engagement follows the same discipline. In fact, this runs from first assessment to final handover.
Engineering-first, not sales-first.
Therefore, you receive a detailed condition report and scope recommendation. This applies regardless of whether you proceed with INGSOL.
During Phase One, our engineers visit your site. They conduct a systematic assessment of the machine. For example, this covers electrical systems, mechanical condition and control architecture. It also covers safety compliance and performance data. We document what is working and what is failing. In addition, we identify what is causing your symptoms.
During Phase Two, we develop a detailed Retrofit and Upgrade Engineering scope. Importantly, this scope addresses root causes, not just symptoms. We then produce the full engineering design. This includes control architecture, electrical schematics and mechanical drawings. Component specifications and a project timeline complete the package.
Teams build control panels, sub-assemblies and pre-wired components off-site. Typically, this happens wherever possible. Teams also test them before they reach your factory. As a result, on-machine downtime drops significantly. PLC programs get developed, simulated and validated first. Nobody writes code on-site during a shutdown.
Our engineers execute the Retrofit and Upgrade Engineering work on-site during Phase Four. Throughout, they work to the planned shutdown schedule. Electrical installation, mechanical fitment and system integration happen next. The same engineers who designed the Retrofit and Upgrade Engineering scope carry out commissioning. Therefore, no handover gap causes lost information or surprises.
Why INGSOL
Why Flexible Packaging Manufacturers Choose INGSOL for Retrofits & Upgrades
We Work Across Every Platform
Our Retrofit and Upgrade Engineering covers Siemens, Rockwell, Schneider and B&R. Other major PLC platforms fit too. In addition, we work with AC, DC, servo and stepper drive systems. As a result, your Retrofit and Upgrade Engineering fits your infrastructure, not ours.
We are Engineer Solutions, Not Packages
Our Retrofit and Upgrade Engineering team understands blown film lines at the process level. The same holds for printing machines. In addition, we understand lamination lines, slitting machines and process equipment this way. Therefore, we solve process problems, not just component problems.
We Own Performance Outcomes
Our Retrofit and Upgrade Engineering work never ends at installation. Instead, we stay involved through commissioning, validation, training and support. As a result, your performance objectives actually get achieved.
Lower Cost Than OEM Upgrades
As an OEM machine upgrade alternative, INGSOL delivers high-quality upgrades. In addition, we do this without OEM overhead costs. In addition, long-term reliability stays intact throughout.
Long-Term Partnerships
Our customer relationships continue well beyond project completion. In addition, ongoing technical support and performance improvement initiatives keep the relationship active.
Connect with us to explore Retrofit and Upgrade Engineering tailored for your business.
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