The modernization of existing machinery is becoming increasingly important when it comes to efficiency and longevity. We have developed a retrofit solution for a Ferag MultiDisc MTD + ZSF that not only modernizes the system but also makes it future-proof.
The reason: discontinued PLC controllers and drive regulators. Rather than investing in costly new equipment, we provided a cost-effective alternative to a complete replacement by using our custom-developed software to maintain – and even enhance – the machines’ functionality and parameter structure despite the integration of new components.
Our project followed a systematic, step-by-step approach to ensure successful modernization and optimization:
1. Preparation
We began with a comprehensive condition analysis to assess the current state of the machines and identify potential weak points. Any necessary wear parts were replaced, followed by a thorough cleaning to establish a solid foundation for the retrofit.
In addition, new mounting plates were manufactured and pre-assembled in advance to make subsequent installation more efficient.
2. Dismantling and Modernization
Next, the old control cabinets were disconnected and dismantled. The newly manufactured and pre-assembled mounting plates were then integrated into the MTD and ZSF control cabinets.
During modernization, we equipped the MTD lifting arms with inclination sensors to ensure a constant product flow. For the disc carrier locking system, we replaced the pneumatic cylinders with sensor-compatible models to maximize safety and prevent production downtime.
We also replaced the outdated 7-inch display on the ZSF unit with a modern 10.4-inch B&R display, featuring a new, user-friendly interface.
3. Software Updates
To further optimize operation and maintenance, several software enhancements were implemented.
This includes the option for remote access via a secure VPN tunnel, enabling quick troubleshooting and remote maintenance.
We integrated B&R Safety components to monitor safety-relevant signals and developed a new intuitive user interface that simplifies parameter management.
Parameter sets can now be downloaded, stored, and reloaded as needed — significantly reducing setup times and allowing quick software adjustments.
This structured approach enabled us to modernize the machines efficiently while improving safety, usability, and system integration.
The Benefits of the Retrofit
• Future-proof: Extended service life through replacement of discontinued components.
• Robust: Reduced number of electronic wear parts for higher operational reliability.
• Cost-efficient: A smart, economical alternative to new equipment.
• Flexible: Easily adaptable to individual customer requirements.
If you are planning to modernize your machines, replace discontinued components, or implement custom solutions, feel free to contact us – we will find the right solution for you!
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