Industrial Retrofit: Modernize without replacing

What is industrial retrofit?

Industrial retrofit involves modernizing existing production equipment by integrating new technologies, without replacing the machine’s core mechanical infrastructure. This practice enables the addition of digital functionalities, performance optimization, or compliance with new standards (safety, environmental, quality) at a lower cost.

In concrete terms, it means giving your machines a second life by equipping them with sensors, connectivity, or intelligent control systems.

Why adopt retrofit in industry?

1. Cost control

Investing in new equipment is expensive and often requires production downtime. Retrofit significantly reduces capital expenditure while extending the lifespan of industrial assets.

2. Reduced production downtime

Replacing a machine means stopping production. Retrofit can be done faster, and often without major disruption, resulting in improved productivity.

3. Compliance with standards

Retrofit allows older machines to meet current regulations (e.g., CE safety standards, environmental or quality compliance), helping you remain competitive and avoid penalties.

4. A stepping stone to Industry 4.0

Retrofit paves the way for gradual digital transformation. By adding connected sensors and monitoring software like KEYPROD, retrofitted machines become intelligent, communicative, and traceable in real ti

What are the concrete benefits for manufacturers?

A well-executed retrofit allows you to:

✅ Monitor the performance of both old and new machines
✅ Identify the root causes of downtime or underperformance (e.g. time losses, failures, micro-stops)
✅ Optimize maintenance scheduling
✅ Reduce your carbon footprint by minimizing material and energy waste
✅ Maximize the value of your existing equipment rather than replacing it
✅ Engage teams in analysis and continuous improvement

Retrofitting with KEYPROD: Connect all your machines, effortlessly

At KEYPROD, we believe every machine deserves to be heard to unlock its full productive potential.

Our plug-and-play industrial production monitoring solution is based on the rapid installation of non-intrusive sensors that magnetically attach to your machines, no modifications, no wiring, and no connection to the PLC required.

With our IoT devices, KEYNETIC and KEYVIBE, connected to our dedicated web platform, you gain a complete overview of your shop floor activity in just minutes, regardless of your machines’ age, brand, or technology.

Our solution allows you to:

👉 Monitor machine activity in real time, independently from existing systems
👉 View key performance indicators (OEE, downtime, cycle time, etc.) on customizable dashboards
👉 Receive proactive alerts in case of anomalies or deviations to boost responsiveness
👉 Digitize your workshop easily, with no IT infrastructure, no wiring, and zero complexity

So, why choose KEYPROD?

By enhancing the intelligence of your equipment, KEYPROD delivers a fast and accessible digital retrofit, no major investment, no prolonged downtime, ensuring a smooth transition to the connected factory.

Testimonials: Retrofit in action

Several manufacturers have already trusted KEYPROD to retrofit their equipment:

Proform:

Proform faced frequent downtime due to format changes and hard-to-detect micro-stoppages.
By connecting its machines with KEYPROD, the company was able to precisely analyze production cycles and uncover hidden time losses.

Results:
✅ 70% reduction in format change-related downtime
✅ Optimized micro-stoppages
✅ Dozens of production hours regained
✅ Clear boost in competitiveness

SA2M:

SA2M had only a partial view of its losses, with OEE stuck at 40–45% due to undetected stoppages and cleaning times.
With accurate and real-time data from KEYPROD, the company reallocated resources, eliminated waste, and reorganized production flows.

Results:

✅ 35% OEE improvement without new investment
✅ One machine removed
✅ Increased overall production

L'Union des Forgerons:

L’Union des Forgerons was dealing with bottlenecks that limited machine utilization.
With KEYPROD, the company gained a clear view of constraints and was able to rebalance the workload.

Results:

✅ +10 to 15% increase in machine capacity
✅ Bottlenecks identified and eliminated
✅ Smoother production flow

Don't replace your machines, reshape their future

Retrofit isn’t just a transitional fix; it’s a forward-looking strategy. By transforming your existing equipment into connected machines, you step into the era of Industry 4.0, without disruption or risky investment.

Want to try KEYPROD for free?
Request your free trial now and see how KEYPROD can turn your machines into true performance drivers.