Sustainable production through retrofit — a conversation with Dr. Arne Wall from Adaept Engineering

Why we were delighted to receive the invitation

The Transformation Academy of the REFA regional association of Mecklenburg-Western Pomerania brings practitioners and researchers together when it comes to climate goals and competitiveness. For us as an engineering firm with roots in university research, this is the perfect stage to share experiences from projects such as OPTIMUM or our OPC UA software for microcontrollers — without buzzword bingo.

Retrofit in a nutshell

Retrofit means retrofitting existing machines with modern hardware and software to increase their connectivity and level of automation. This approach is sustainable because it extends the life of plants and thus reduces the need for new raw materials and CO₂ emissions for new buildings. In addition, the data obtained creates transparency about savings potential and helps to optimize energy consumption. Because resource-saving maintenance is possible through remote diagnostics, there is no need for time-consuming on-site technician assignments.

Suitable entry scenarios and technical requirements

In an interview, Dr. Wall describes typical entry-level scenarios. Systems that have not yet reached the end of their life cycle, already have sensors and whose interfaces are documented are particularly suitable. Structured recording of operating data is particularly worthwhile in energy-intensive processes, because on this basis, consumption can be reduced and product quality improved. According to Dr. Wall, companies, particularly small and medium-sized companies, often approach the topic with a mixture of curiosity and skepticism. Common prejudices are that relevant data points are not accessible at all or that dead spots prevent stable transmission. Here, Dr. Wall refers to store-and-forward mechanisms with OPC UA historians, which buffer data on site and only transfer it when the connection is reliable.

Funding programs reduce costs

Costs are another point. Dr. Wall emphasizes that various funding programs, from energy-saving investments to publicly funded research projects, make it easier to get started financially. Adaept Engineering supports customers by analyzing suitable funding programs and accompanying the implementation of individual research projects. According to Dr. Wall, retrofit does not displace internal staff, but rather a restructuring of tasks. Routine activities are eliminated, while data analysis, predictive maintenance, and workflow optimization are becoming more important.

Retrofit as a long-term innovation platform for industry

The podcast also takes a look ahead. Adaept Engineering sees retrofit not just as a bridge technology until all new machines are connected per se, but as a permanent innovation platform. When machines have uniform semantic interfaces, new software functions or AI algorithms can simply be rolled out later without having to touch the hardware. The result is a production environment in which existing systems, modern machines and cloud-based services work seamlessly together — a decisive step on the way to a truly sustainable, data-driven industry.

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The complete episode “Sustainable Production through Retrofit” with Dr. Arne Wall is available on popular podcast platforms. Anyone who would like to find out more about specific retrofit projects or check how to digitally upgrade their own system can directly arrange a non-binding initial consultation with Adaept Engineering.

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