Many existing automated testing systems are built on a robust mechanical structure and can continue to provide reliable service for many years. However, aging control electronics, obsolete software, limited automation capabilities and unavailable spare parts often reduce productivity, increase maintenance costs and make it difficult to meet today's quality and testing requirements.

Walter+Bai offers comprehensive retrofit and modernization solutions that upgrade existing testing systems to the latest state of the art. Depending on the condition of the equipment and the customer's objectives, a modernization may include the replacement of controllers, electronics, servo drives, hydraulic components, measuring systems, safety equipment and testing software. Existing systems can also be upgraded with automatic specimen identification, barcode or RFID technology, robotic specimen handling, automatic gripping systems, specimen magazines, portal loaders, automatic dimensional measurement, weighing stations and complete laboratory automation.

The objective of every retrofit project is to maximize the value of the customer's existing investment. By increasing automation, testing capacity, productivity and repeatability while reducing manual intervention and operating costs, many existing testing systems can achieve a level of performance comparable to that of a modern new installation.

However, not every testing system is a suitable candidate for modernization or complete automation. The mechanical condition of the machine, its structural design, remaining service life, availability of spare parts and the desired level of automation must all be carefully evaluated. Furthermore, the modernization of a complete automated testing system usually requires the equipment to be dismantled and transported to Walter+Bai's manufacturing facility, where all mechanical, electrical and software modifications can be carried out under controlled workshop conditions. After assembly and comprehensive factory acceptance testing, the system is shipped back to the customer's site for installation and recommissioning. Depending on the size and complexity of the system, transportation, dismantling, reassembly and commissioning may represent a significant part of the overall project cost. In such cases, investing in a completely new automated testing system may prove to be the more practical and economically attractive solution.

For this reason, every retrofit project begins with a detailed technical and economic assessment. Our engineers carefully evaluate the existing equipment, discuss the customer's current and future testing requirements and determine the most suitable solution. Whether the recommendation is a targeted modernization, a complete retrofit to fully automated operation or the replacement by a new testing system, Walter+Bai provides independent engineering expertise focused on delivering the technically and economically best solution for every application.