Retrofits & Upgrades

After

Before

Retrofits & Upgrades That Rebuild Performance.

Your flexible packaging machines are capital investments built to last decades. INGSOL’s retrofit and upgrade engineering extends that investment by modernising controls, rebuilding electrical systems, and improving mechanical precision without the cost, complexity, or downtime of full machine replacement.

What We Do

Retrofit & Upgrade Engineering for Flexible Packaging Machinery

Not all retrofits are the same. INGSOL scopes each engagement precisely around the real problem, whether that’s an obsolete control system, a mechanical performance issue, an electrical safety risk, or 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

We have direct retrofit and upgrade experience across the major categories of flexible packaging equipment, from print and lamination to extrusion and converting.

Blown Film Lines

Winder, haul-off, cage, cooling, PLCs, drives

Printing Machines

Lamination Machines

Bonding optimisation, PLC upgrades, speed control

Slitter

Rewind tension control, speed enhancement, accuracy

How We Work

Our Retrofit Engineering Process

INGSOL’s retrofit process is structured to eliminate the two things that kill retrofit projects: scope surprises and commissioning failures. Every engagement follows the same discipline, from first assessment to final handover.

Engineering-first, not sales-first.
Our machine assessment is conducted by engineers, not account managers. You get a detailed condition report and retrofit scope recommendation, regardless of whether you proceed with INGSOL.

Phase One

Machine Condition Assessment

Our engineers visit your site and conduct a systematic assessment of the machine: electrical systems, mechanical condition, control architecture, safety compliance, and production performance data. We document what is working, what is failing, and what is causing your symptoms.

Phase Two

Retrofit Scope & Engineering Design

Based on the assessment, we develop a detailed retrofit scope that addresses the root causes of your machine's performance problems ,not just the symptoms. We produce the engineering design: control architecture, electrical schematic, mechanical drawings, component specifications, and a project timeline.

Phase Three

Off-Site Build & Factory Test

Where possible, new control panels, sub-assemblies, and pre-wired components are built and tested off-site before arriving at your factory. This reduces on-machine downtime significantly. PLC programs are developed, simulated, and validated before installation ,not written on site during a shutdown.

Phase Four

On-Site Installation & Commissioning

Our engineers execute the retrofit on site, working to the planned shutdown schedule. Electrical installation, mechanical fitment, system integration, and control commissioning are carried out by the same engineers who designed the retrofit , no handover, no information loss, no surprises.

Why INGSOL

Why Flexible Packaging Manufacturers Choose INGSOL for Retrofits & Upgrades

We Work Across Every Platform

We support Siemens, Rockwell, Schneider, B&R and other major PLC platforms along with AC, DC, Servo and Stepper drive systems.

We are Engineer Solutions, Not Packages

Our team understands blown film lines, printing machines, lamination lines, slitting machines, and process equipment at the process level, not just at the component level.

We Own Performance Outcomes

Our work does not end at installation. We stay involved through commissioning, validation, training, and support to ensure performance objectives are achieved.