Overhead conveyors run for decades, but products, volumes and processes change. A retrofit adapts the conveyor to the new needs while keeping what still works.
Signs it is time to upgrade
- Output targets have grown beyond the line's capacity
- Short stoppages in one process stop the whole line
- New products do not fit the carriers or the route
- Spare parts for drives or controls are obsolete
- Breakdowns and chain wear are increasing
- There is no tracking or production data from the conveyor
Common retrofit projects
| Upgrade | What it achieves |
|---|---|
| Add accumulation buffers | Decouples processes so short stops do not spread |
| Convert sections to power and free | Stops, queues and routing where a chain conveyor ran |
| Add switches and parallel stations | More capacity at bottleneck stations |
| Replace chain and wear parts | Restores reliability on a worn system |
| Upgrade drives and take-ups | More capacity, better load sharing |
| New carriers | Fit new products or improve handling |
| Control upgrade | Modern PLC and HMI, diagnostics, tracking, MES link |
| Lift and lower stations | Better ergonomics and transfers to floor systems |
What can be reused?
Support steel and track are often in good condition after many years. Reuse depends on:
- Chain class and track type matching the new requirements
- Condition of track, drives and structure (survey and measurement)
- Load capacity for heavier new products
- Availability of compatible parts
Plan the shutdown
The biggest risk in a retrofit is production loss. Good planning includes:
- Survey and as-built drawings before design
- Pre-fabrication and pre-assembly of new sections
- Work in phases during weekends, holidays or planned shutdowns
- Temporary routes or manual handling where needed
- Commissioning plans for each phase
Control retrofits
Replacing an obsolete control system can be done while keeping the mechanics. New controls add diagnostics, carrier tracking and data for MES and OEE. See controls and automation and RFID carrier tracking.
Start with a survey
A site survey measures the existing system, records its condition and identifies bottlenecks. With that data, the upgrade can be designed and priced accurately. HITREE carries out retrofits and extensions of overhead conveyors; contact us to arrange a survey.
Worked example: adding a buffer
A coating plant's overhead chain conveyor stops every time unloading falls behind, which also stops loading and the booth. A retrofit adds a power and free section at the unloading end with a buffer of 12 carriers. Short delays at unloading no longer reach the booth, and line output rises without changing the process equipment.
Retrofit project steps
- Site survey and measurement of the existing conveyor
- Bottleneck analysis and target definition
- Concept and budget
- Detailed design and pre-fabrication
- Installation in planned shutdowns
- Commissioning and ramp-up per phase
Retrofit or replace?
| Situation | Usually better |
|---|---|
| Track and structure in good condition | Retrofit |
| Bottleneck at a few stations | Retrofit |
| Loads far above original design | Replace or major rebuild |
| Building layout changing completely | New conveyor |
An overhead conveyor retrofit is often the fastest way to more output from an existing line.
