Upgrades and Retrofits
Upgrades and Retrofits
Smarter Solutions for Your Facility
At Systems in Motion, we see every day how old equipment slows down good businesses. Our headquarters are in Elgin, Illinois, and we work with facilities across the country. Many warehouses still depend on systems that were built years ago. These systems often break down, cost more to maintain, and cannot keep up with today’s demand.
Our upgrades and retrofits service gives you a way forward. You do not need to spend millions on a new system. Instead, we replace outdated parts, add new controls, and improve automation. This gives you the power of modern equipment without the high cost of starting over.
We work with food and beverage plants, e-commerce fulfillment centers, parcel delivery networks, manufacturers, and 3PL companies. No matter the industry, our goal is the same: help you move product faster, safer, and at a lower cost. With teams in Texas, Florida, Arizona, Wisconsin, Indiana, and other states, we can respond quickly wherever you need us.
Why Choose Upgrades and Retrofits
Buying a new system is not always the best answer. Many times, the foundation of your equipment is still strong. It just needs the right updates. Our upgrades and retrofits give you a clear path to better performance.
Here are the benefits you can expect:
- Longer equipment life – We replace parts, motors, drives, and controls so your system feels new again.
- More throughput – Modern conveyors, sorters, and automation software increase your speed and accuracy.
- Lower repair costs – New components break down less often, which saves time and money.
- Energy savings – Updated drives and controls use less power and deliver a better return on investment.
- Flexibility for growth – Retrofits prepare your facility to handle higher demand and new product lines.
- Less downtime – With new controls and sensors, your equipment runs more reliably, keeping your operation on schedule.
Every upgrade we install is built for your goals. Some clients want faster order picking. Others need safer work areas or better use of limited space. We design our retrofits to meet those needs, not a generic standard.
How the Upgrade Process Works
We start by listening. Before we change anything, our engineers study how your system runs today. We look at your equipment, your floor plan, and your production goals. Then we show you where upgrades will have the most impact.
Common upgrade projects include:
- Conveyor retrofits to improve speed, reduce noise, and lower energy use.
- Control system upgrades that replace outdated PLCs and add smarter software.
- Sorter replacements that increase accuracy and reduce errors in high-volume facilities.
- Safety improvements such as better guarding, sensors, and warning systems.
- Software integration that allows your WMS or ERP to connect with advanced automation.
Once we agree on the plan, our team installs the upgrades on-site. We work to keep downtime as short as possible. Many projects can be done in phases so your operation keeps running while we make improvements.
Real Results from Our Work
We have seen the power of upgrades many times. In one food and beverage facility, we replaced outdated conveyors and controls. The system now processes more than one million square feet of product with greater accuracy and less energy use.
In another project, a parcel distribution center needed to push more packages through a small footprint. After a retrofit, the system moved 70,000 packages in just eight hours. That client did not need a new building or a new system. They just needed the right upgrades.
These stories show how smart improvements can make a huge difference without a massive investment.
Our Experience
Since 1996, Systems in Motion has supported clients with design, installation, and aftermarket care. We are a turnkey systems integrator with decades of hands-on experience. Our team has worked on hundreds of projects, from small upgrades to full-scale retrofits of national distribution centers.
We are proud members of MHEDA, MHI, and WERC. For more than 12 years, we have received the MHEDA MVP award. This award recognizes companies that deliver excellence in customer service, employee training, and supplier relationships. We hold that standard every day.
What sets us apart is our commitment to long-term support. We do not walk away after the project is done. Our aftermarket services include parts supply, maintenance programs, and 24/7 technical help. When you work with us, you get a partner who will stand by your system for years.
Let’s Talk About Your Needs
If your equipment is slowing you down, you do not have to wait until it fails. Call us at (800) 678-9091 or fill out our online contact form. Our upgrades and retrofits will give your system new life and keep your business moving forward.
At Systems in Motion, we believe in building relationships one solution at a time. Let us show you how the right upgrade can make the difference for your facility.
FAQS
How long does an equipment retrofit or upgrade typically take?
The full length of a retrofit or upgrade depends on the scope of the project. A typical timeline is 6 to 12 weeks, including the Assessment, Procurement, Implementation, and Commissioning. For a more precise timeline, contact our team to discuss your needs.
Is retrofitting cheaper than a full system replacement?
Typically, yes. If it isn’t we will identify options for you, By strategically retrofitting existing systems you can extend their usefulness and improve your return on investment.
What downtime is required during a retrofit?
Downtime is only required during the Implementation and commissioning stages. Much of the work can be completed during off-hours, so it is reasonable to 1 to 5 weeks of actual downtime. The scope and requirements of each project are unique, so timelines differ, but we always seek to minimize the downtime required.
Can legacy systems be retrofitted with modern control technology?
Yes. For example, the Hytrol E24 retrofit cable allows a newer 3.5 control card to be connected to legacy 3.0 motors—enabling upgrades without replacing motors. Contact our team today to learn about more options to extend the life of your equipment.
Does retrofitting bring systems up to compliance or safety standards?
Yes. A well-planned retrofit is an opportunity to bring existing systems up to current safety and compliance standards. During retrofit projects, Systems in Motion evaluates each facility’s equipment for outdated guarding, emergency stops, sensors, and operator interfaces. Upgrades often include:
- Improved guarding and interlocks to meet modern OSHA and ANSI requirements.
- Enhanced safety sensors and warning systems that protect operators and maintenance staff.
- Updated controls and wiring that comply with current NFPA and UL standards.
- Documentation and labeling that support safe operation and inspection readiness.
In most cases, retrofitting brings older systems into alignment with current safety codes and industry best practices, reducing liability and improving worker protection while keeping the existing infrastructure in use.
Are there industry-specific retrofit solutions, like for food & beverage or pharmaceuticals?
Systems In Motion has experience with Greenfield, Brownfield, and Retrofit projects across multiple industries, including Food and Beverage, Manufacturing, Distribution, 3PL, Fulfillment, and more. Our experienced team can help you identify and implement the retrofits that will be most effective for your industry and facility.
What are the pros and cons of choosing a retrofit over a full replacement?
Pros: Cost-effective—e.g., preserving motors via retrofit cable reduces replacement costs; Minimizes downtime during upgrades.
Cons: Potentially limited by the existing installation footprint, whereas a fully new installation may offer more flexibility.
How can I get support after my system is upgraded or retrofitted?
Systems In Motion provides Aftermarket Services, including flexible service and care programs, 24/7 lifecycle support, parts supply, and technical/mechanical assistance.
What stages are involved in a retrofit project?
Systems In Motion’s Design / Consulting / Analytics / Engineering process applies to retrofit projects and includes:
- Evaluating current operations
- Establishing project goals
- Identifying performance characteristics such as flow rates, flexibility, storage, and maintenance
- Recommending technology and automation appropriate for retrofit scenarios
Can I maintain growth flexibility following a retrofit?
Yes. Systems In Motion focuses on facility design that integrates future goals and scalable solutions; including Greenfield, Brownfield, and Retrofit projects.
“Systems in Motion has not only solved our problem but has also set us up for future success. Their innovative approach and commitment to excellence have made all the difference.”
“Systems in Motion has been a valued partner of WireCrafters for many years. Their expertise and knowledge of the material handling industry is unmatched."
“Systems in Motion has been a trusted partner of KeHE Distributors for years, with several mid to large projects. KeHE Distributors truly appreciates the value and hard work which Systems in Motion brings to every project.”
“Systems in Motion was a true partner to Acieta. They displayed the capabilities and integrity that is so critical to an understanding both big picture ideas and executing the small details. They deliver!”
“Your techs are great, very friendly and has a lot of knowledge. When needing parts, they are very helpful in giving you part numbers if you want to repair yourself. They help you over the phone to solve a problem before sending someone out. Fast service when needed.”
Success Stories
Optimize Efficiency & Productivity with Automated Material Handling Systems and Supply Chain Solutions
Rapid growth led MJ Holding, the largest North American distributor of trading cards, to determine it was time to combine