New systems, retrofits

Whether it’s a new system, system expansion, or retrofit – it’s based on a precise requirement analysis that considers all relevant factors, including location of use, function, and the state of the art. Our engineers use this analysis to develop exactly the solution you need. They define the level of system integration to fit your needs.

Comprehensive approach

Our all-inclusive services in automation include the consulting, planning, and design of industrial solutions in electrical engineering, automation, mechatronics, and information processing. And if you wish, we can also provide these services as a general contractor, for such diverse projects as incorporating MSR technology, vertical and horizontal integration, and motion control applications.

Increased production through modernization

In addition to equipping new systems, updating existing systems with retrofits is also a field of growing importance.

In this context, HEITEC works primarily in the areas of special machines and machine tools, warehouse logistics, and the manufacturing-related aspects of production operations. We provide customized solutions, whether it’s at the control level with actuator and sensor engineering and intelligent drive technology or at the technical process control level with process visualization and optimization – all the way to connecting to the
ERP level, for example with SAP. For these projects, our subsidiary HEISAB offers the support of more than 30 SAP specialists.

Software-based support for engineering processes

An important productivity driver in system modernization is software-based support for engineering processes using virtual models of machines, systems, robot applications, and material flows.

This makes it possible to develop and test procedures on machine components more efficiently, regardless of the degree of completion of the machine or system.

When reconfiguring existing systems, HEITEC runs desk tests on the automation software so that it can be downloaded to the system without error and with the least possible disruption of the production process.


Machine and plant availability declines with length of use.
Components will fail more regularly, and many of the hardware components used will already have been discontinued and be difficult to obtain on the market. In addition to the problems of spare parts supply, it will also become increasingly difficult to find specialists who are still expert in the old technology.

At the same time, technology continues to advance and market demands continue to grow. By replacing old components and adding new, up-to-date technological refinements, existing plant can be optimized and restored to the start of the art.

When it comes to upgrading older plant, HEITEC focuses on special machines and machine tools, as well as warehouse services and the manufacturing-level areas of production facilities.

HEITEC provides customer-specific solutions, from the control level with actuator and sensor technology and intelligent drive technology to the technical control level with process visualization and optimization, and connection to the ERP level, e.g. SAP.

It has a particular focus on providing end-to-end service, from analysis to design and implementation.

  • Recording the condition of the existing plant
  • Risk assessment in terms of plant safety
  • Analysis of plant availability if faults occur
  • Analysis of potentials
    • Safety analysis (does the technology still comply with current safety regulations?)
    • Throughput analysis (analysis of entry and retrieval processes)
    • Fault analysis (which faults, how often, and where the greatest risks occur)
    • Review of spare part availability
  • Recording potential savings
  • Drawing up an upgrade plan based on customer requirements


An inventory and analysis of the condition of the plant generally reveals any weak points very quickly.

Based on this analysis and in collaboration with the operators, an upgrade plan is drawn up that most effectively takes account of customer requirements. The upgrade schedule that then follows describes all the processes and technical functions for each phase, gives the project a structure, and establishes a sequence for all activities at both the customer and supplier end.

The specification of the upgrade schedule forms the basis for the plan that will subsequently be implemented in practice. Plant operators can use this to plan the necessary investment.

A digital model can be used at the implementation stage to ensure the planned conversion timeframes are observed.

  • Initial analysis and inspection of the existing plant
  • Coordinate implementation plans
  • Budget estimate for planned work
  • Draw up specifications for work needed in detail
  • Draw up fixed price offer with a realistic schedule for implementation
  • Work out fine specifications in collaboration with the operator
  • Safety/risk assessment in collaboration with the operator
  • Hardware planning
  • Software configuration
  • Draw up a virtual model
  • Test and pre-acceptance using the digital twin
  • Conversion and commissioning of individual function areas in several stages

Industrie 4.0 creates additional opportunities like increased productivity, predictive maintenance, and networked production, even for older machines and plant.

Upgrading machines and plants includes fitting them with state-of-the-art communications and sensor technology. This makes it possible to record and analyze production data, while also enabling networking within the production system.

The result is that machines and systems are ready for the future, with many more years of productive use.

An important lever for productivity when upgrading a plant is software-based support for engineering processes using virtual models of machines, plant, robot applications, and material flows.

That means machine component workflows can be developed and tested more efficiently, regardless of the level of completion of the machines and plant.

The strategy of running a “real” commissioning process on the virtual model from HEITEC means all current and future workflows can be simulated in the relevant production environment in real time, and controlled using the original automation software.

This achieves a higher roll-out quality for automation and drive solution software, and identifies workflow errors at an early stage.

HEITEC tests the automation software for older system conversions at the desktop, to ensure it can be installed on the plant without errors, and with only minimal interruptions to the production process.