1. Introduction
In the current industrial environment in the Benelux, operational efficiency is under constant pressure from rising energy costs, aging infrastructure and stricter EU environmental regulations, such as the EU Ecodesign Directive (2009/125/EC). Many transport systems in factories still function based on technology from the 1990s or the beginning of this century. Although these systems still technically function, they lead to unnecessary energy consumption, increased maintenance costs due to worn mechanical parts and limited options for condition monitoring. Modernization is essential to maintain competitiveness and to comply with modern safety standards such as NEN-EN-ISO 13849-1.
2. Evaluation of legacy systems
Before retrofitting, a thorough assessment of the current infrastructure must be conducted. The following table shows the main criteria for this evaluation.
| Criterion | Status | Risk | Action |
|---|---|---|---|
| Energy consumption | Above market average | High operating costs | Replace drives |
| Availability of parts | Limited (obsolete) | Prolonged downtime | Preventive replacement |
| Safety | Not compliant | Personnel risk | Upgrade safety circuits |
| Condition Monitoring | Absent | Unexpected defects | Add sensors |
3. Modern alternatives and technological leaps
The move to modular drives offers a significant improvement in both performance and flexibility. Modern components, such as the FIBRO 2490.12.00420.025, integrate mechanical precision with advanced electronic control. In the table below we compare the classic approach with the modern approach.
| Component | Classic Technology | Modern Technology | Advantage |
|---|---|---|---|
| Drive | Direct motor/worm gearbox | Modular servo drive (including FIBRO) | Higher efficiency, precision |
| Sensors | Mechanical limit switches | Inductive/laser sensors (IoT-ready) | Diagnostics, reliability |
| Energy management | Drain via resistors | Energy recovery (regeneration) | Lower energy bill |
4. ROI calculation and TCO analysis
The objection that "the old system still works" ignores the Total Cost of Ownership (TCO). An upgrade is not just an expense, but an investment. Below are realistic figures for a typical upgrade of a 50 kW transmission system:
- Energy savings: A 15% reduction in consumption (50 kW * 15% = 7.5 kW). At 4,000 operating hours per year and an energy rate of € 0.25/kWh, this results in a saving of € 7,500 per year.
- Maintenance costs: Preventive maintenance and modular components reduce annual maintenance time by 200 hours. At an hourly rate of €85, this is a saving of €17,000 per year.
- Downtime reduction: A reduction of 50 hours of unplanned downtime per year. At a cost of €2,500 per hour of downtime, this is a profit of €125,000 per year.
Total annual savings: €149,500. With an investment of €300,000, the payback period (ROI) is less than 2.5 years.
5. Implementation plan: A phased approach
To minimize production disruptions, we take the following steps:
- Planning and Audit: Detailed measurement of vibration, power consumption and mechanical wear.
- Procurement: Purchasing of certified components, including FIBRO 2490.12.00420.025 for critical positions.
- Installation: Phased rollout during planned production shutdowns.
- Commissioning: Integration into the existing PLC network and validation of the safety circuits.
6. Technical challenges and solutions
A common challenge is the integration of new drives with legacy PLC systems. We recommend the use of universal gateways (Profibus to PROFINET or Ethernet/IP) to facilitate this bridging without replacing the entire PLC infrastructure.
7. Practical example
In a recent case study at a packaging company in the Benelux, a 20-year-old transport system was upgraded. By replacing outdated motors with highly efficient modular drives and adding smart sensors for condition monitoring, the MTBF (Mean Time Between Failures) increased from 8,000 to 45,000 hours, while energy consumption fell by 18%. UNITEC-D supplied both the engineering expertise and the replacement components.
8. Commissioning and Validation
After installation, formal validation is required. This includes:
- Thermal inspection: Check for heat development in drives and control cabinets.
- Safety validation: NEN-EN-IEC 60204-1 compliance testing for emergency stops and safety functions.
- Performance test: Measurement of cycle times and precision under load.
9. Conclusion
Modernization of transport systems is not a luxury, but a necessity for a reliable and profitable production process. By making targeted investments in modular drives and smart technology, you not only increase productivity, but you also meet the strictest safety and energy standards. For technical advice and components, visit our UNITEC-D E-Catalog.
10. References
- NEN-EN-ISO 13849-1: Safety of machines - Safety parts of control systems.
- NEN-EN-IEC 60204-1: Safety of machines - Electrical equipment of machines.
- EU Regulation 2019/1781 (Ecodesign requirements for electric motors and speed controls).
