01Initial Situation
A retrofit was planned for ASYATÜRK's filling machine. The customer specifically requested that some previously used, still serviceable parts be retained in the new system. This defined the project's starting point: the retrofit would work with existing components rather than rely entirely on new equipment.
This approach required assessing the machine's components individually first. The control architecture could not be redesigned until it was clear which drive, relays and other automation components could be reused. The first stage therefore established the usability of the customer's existing hardware.
02Applied Solution
The machine's drive, relays and other suitable automation components were inspected; serviceable parts were identified and included in the retrofit. Each component's role and connections in the new arrangement were considered individually, and existing equipment was reintegrated into the system.
- Inspection of the existing drive, relays and automation components
- Reusable parts included in the retrofit
- Reorganising controls around retained components
During the retrofit, controls were arranged to work with retained components. The drive and relays were connected according to their roles in the new system, and machine operation was re-established. The customer's hardware retained its function and continued in use on the retrofitted machine.
03Technical Assessment
The key engineering consideration was treating existing hardware as an input to the new system design rather than a limitation. Each retained component's role and connection were assessed together, and the control architecture was designed around how these components operate.
Assessing serviceable equipment avoided unnecessary replacements. Following the customer's explicit request, the retrofit reused existing hardware and included only necessary modifications. Connections and functional roles were aligned between the old and reorganised architecture.
04Return to Operation
After reusing existing hardware and completing the necessary retrofit work, the filling machine was operational again. The drive and relays returned to service in their roles within the new arrangement.
The system was completed and delivered in accordance with the customer's request to retain existing parts. The resulting machine continued using the customer's serviceable equipment with a reorganised control architecture.
05Project Outcomes
“We specifically wanted our existing drive and relays to be used. Restoring the machine while making use of these parts was a suitable solution for us.”
İbrahim · Company Representative
