Reviving Old Machines: How IIoT Breathes New Life into Legacy Equipment
- Chinmay
- January 9, 2025
- Industrial IoT
- Data Analytics, IIoT, Industrial Internet of Things, IoT Gateways, Legacy Equipment, manufacturing, predictive maintenance, Retrofitting, sensors
- 0 Comments
Manufacturing companies are always looking for ways to boost production, reduce downtime, and improve efficiency. Thanks to the Industrial Internet of Things (IIoT), businesses can now upgrade their old machines without investing in brand-new equipment. This process, known as retrofitting, allows companies to modernize their operations cost-effectively.
Why Aren’t More Manufacturers Using IIoT?
Even though the global IIoT market was valued at over $263 billion in 2021 and is expected to reach $1.11 trillion by 2028, less than one-third of manufacturers are fully utilizing IIoT technologies. The reasons often boil down to technical and organizational challenges.
Technical Challenges:
- Managing different types of systems and software can be complicated.
- Deciding which technologies to use for tasks like supply chain or asset management isn’t always straightforward.
- Companies struggle with where to deploy these systems—whether on-site, at the edge of the network, or in the cloud.
Organizational Challenges:
- Businesses sometimes fail to adapt their processes to make the most of IIoT technologies.
- Without leadership support, IIoT initiatives may remain small-scale and not deliver full value.
- Employees may need training to work with new, data-driven systems.
How Retrofitting Bridges the Gap
Retrofitting involves adding modern sensors, connectivity, and software to existing machines. This upgrade allows old equipment to collect and share data, enabling:
- Better Monitoring: Keep an eye on machine performance in real-time.
- Predictive Maintenance: Anticipate breakdowns before they happen.
- Efficiency Gains: Optimize production processes based on data insights.
Key Components of Retrofitted IIoT Systems
- Sensors: Devices that measure things like temperature, vibration, or pressure. They collect data from the machines.
- IoT Gateways: These act like translators, sending the sensor data to servers either on-site or in the cloud.
- Data Storage and Analytics: Platforms that store the data and analyze it to provide useful insights.
- Data Visualization Tools: Dashboards and apps that present the data in an easy-to-understand format.
Three Ways to Retrofit Your Machines
- OEM Upgrades: Use upgrade kits provided by the Original Equipment Manufacturer. This is often the simplest option if available.
- Custom IIoT Solutions: Work with technology firms to create tailor-made solutions that fit your specific needs.
- Third-Party Retrofit Kits: If the original manufacturer doesn’t offer upgrades, third-party kits can provide both the hardware and software needed.
Moving Forward Without Huge Investments
Completely replacing old machinery can be extremely costly. Retrofitting offers a smart alternative, allowing companies to enjoy the benefits of modern technology without the hefty price tag. As businesses adapt to post-pandemic challenges, IIoT-enabled retrofitting can play a crucial role in achieving operational excellence.
