Table of Contents
Conveyor retrofits are the fastest path to new capacity, and conveyor retrofits often deliver 30–50% of “new-system” gains at a fraction of the capex—when you choose the right scope and sequence. Lafayette Engineering has published extensively on modernization and ROI-driven upgrades; the roadmap below distills what works. LaFayette Engineering+1
Why Conveyor Retrofits Instead of Rip-And-Replace?
- Budget: Swap in smarter controls, targeted sortation, and new MDR zones where they matter most.
- Time-to-value: Weeks—not quarters—to influence peak season.
- Change management: Less disruption to labor and IT; no full re-slotting.
MHI’s technical papers on conveyor/sortation show how targeted additions (e.g., a right-sized divert or accumulation strategy) can rebalance whole lines. See: MHI Conveyor & Sortation Systems resources. media.videos.mhi.org
The Retrofit Ladder (Climb Only as High as Needed)
- Controls Refresh: Modern PLCs, VFDs/MDR with standardized function blocks; add diagnostics and standardized alarms on HMI.
- Sensor & Scan Upgrades: Higher-reliability photo-eyes, smarter barcode logic, dimensioning/weight checks.
- Targeted Merge/Divert Re-timing: Software first; hardware only where you still saturate.
- Accumulation Re-zone: Convert long legacy conveyor into MDR islands with sleep/wake to cut energy.
- Exception Handling: Add a dedicated recycle/QA spur to stop contaminating mainline throughput.
- New Sortation Module: Only if data proves your current sorter is the true constraint.
Safety & Compliance During Retrofits
Any modernization must re-validate guarding, e-stops, permissives, and LOTO procedures. OSHA 1910 standards for machine guarding/power transmission are your baseline—bake them into your retrofit FAT/SAT checklists and HMI alarm logic. OSHA Machine Guarding. OSHA
How to Prioritize Scope (Data-First)
- Map hour-by-hour rates and alarm density to find the real choke points.
- Instrument queue lengths at merges/diverts for a week.
- Simulate timing changes before changing hardware.
- Pilot one span before rolling site-wide.
Cost/Benefit Patterns We See
- Controls + HMI only: Faster fault recovery, fewer nuisance stops, better accuracy.
- Add MDR accumulation: Cuts carton-to-carton impacts, reduces labor “babysitting,” lowers energy.
- Sorter software + divert feedback: Reduces late/early hits; improves service-level consistency.
LEI’s own content shows how strategic retrofits deliver measurable ROI and upgrade paths without scrapping usable steel. LaFayette Engineering+1
Execution Timeline You Can Trust
- Week 0–2: Discovery & data capture
- Week 3–4: Controls/HMI design & emulation
- Week 5–6: Weekend install windows (phased)
- Week 7–8: Ramp & optimization with daily KPI huddles
Post-Retrofit KPIs
- Throughput delta vs. baseline
- MTTR reduction on top 10 alarms
- Mis-sort rate and recycle ratio
- Energy kWh per carton
- Operator interventions per hour
External resource: Georgia Tech OSHA Consultation’s conveyor safety quick guide is a practical checklist to use during retrofit planning: Conveyor Safety — Georgia Tech OSHA. Safety Health Environmental Services
If you’re weighing conveyor retrofits before peak, we’ll help you pick the smallest scope that unlocks the biggest gain.
