As production demands increase and technology continues to evolve, manufacturers face an important question: Should we retrofit our existing liquid filling equipment, or is it time to invest in a new system altogether?
At Apex Filling Systems, we understand the critical role your machinery plays in uptime, output, and profitability. Whether you’re a craft distiller expanding your footprint or a large chemical manufacturer optimizing line performance, making the right decision between retrofitting and replacing can have lasting operational and financial impacts.
Assessing the Condition of Existing Equipment
Before jumping to conclusions, it’s essential to conduct a thorough equipment audit. Key areas to examine include:
-
Mechanical wear and tear (e.g., leaky nozzles, deteriorated seals, or worn actuators)
-
Control system reliability (Are you still running legacy PLCs with minimal support?)
-
Changeover inefficiencies that reduce throughput
-
Downtime frequency and the cost of emergency repairs
-
Obsolete parts availability that may create procurement delays
If your current system has a strong mechanical foundation and modular design, it may be a good candidate for a retrofit. However, if breakdowns are recurring, production is bottlenecked, or your equipment is no longer compliant with safety or regulatory requirements, replacement might be more cost-effective long-term.
When Retrofitting Makes Sense
Retrofitting involves updating specific components—such as controls, sensors, pumps, or software—while keeping the core mechanical structure of your machine intact. It’s ideal when:
-
Your machine frame is structurally sound.
-
You need to integrate modern technology, such as servo-driven nozzles, touch screen HMIs, or remote monitoring.
-
You have limited capital but want to extend equipment lifespan.
-
You’re customizing a line for a new product with similar viscosity or fill requirements.
-
Downtime must be minimized, and you can't afford a lengthy replacement and commissioning process.
A properly executed retrofit can improve fill accuracy, reduce maintenance, and bring your line up to modern standards—often at a fraction of the cost of a new system.
When It's Time to Replace
Despite the appeal of retrofitting, there are times when a full replacement is the more strategic choice. You should consider replacing your filling system if:
-
Repair costs are snowballing, and downtime is affecting delivery schedules.
-
The current equipment cannot meet your new production capacity.
-
You are shifting to a different product type or viscosity that your existing machine can’t accommodate.
-
You require integration with Industry 4.0 platforms and smart factory initiatives.
-
The system no longer complies with updated industry regulations for safety, cleanliness, or explosion-proof environments.
Modern filling machines are faster, more precise, energy-efficient, and can be customized to handle a range of container types, fill volumes, and viscosities.
Long-Term ROI: Don’t Just Compare Price Tags
When deciding between retrofit and replacement, look beyond the upfront cost. Factor in:
-
Labor savings from automation or faster changeovers
-
Reduced material waste from more accurate fills
-
Maintenance cost reductions
-
Downtime avoidance
-
Warranty coverage and support from the OEM
In many cases, the increased uptime and output from new equipment will pay for itself faster than you might expect.
Apex Filling Systems: Helping You Make the Right Move
We know the decision to retrofit or replace isn’t black and white. That’s why Apex offers equipment audits and engineering consultations to help you determine the most cost-effective, future-ready option for your business. Our goal is to maximize your performance and ROI—whether that means refreshing what you already have or designing a custom new solution.
Ready to evaluate your aging equipment?
Contact Apex Filling Systems today to speak with our team and schedule a consultation.