The electrification of industrial machinery offers companies two main routes: retrofitting existing machines or purchasing entirely new electrical equipment. Both options have their own advantages and challenges, with the right choice depending on factors such as budget, schedule, and specific business needs.
For many companies, the difference between retrofitting and new electric machines is crucial for their electrification strategy. Understanding these options helps in making informed decisions that align with operational goals and financial capabilities.
What does retrofit mean for electrical machines?
Retrofitting electric machines involves replacing the existing internal combustion engine with an electric drive system, including battery packs, electric motors, and associated electronic components. This process transforms conventional machines into fully electric variants while retaining the original chassis structure.
The retrofit process involves various technical aspects. The combustion engine is removed and replaced by an electric motor connected to a specially designed battery system. Additionally, control electronics, charging systems, and cooling systems are integrated to ensure optimal performance. For heavy equipment This process often requires customization due to the specific power and energy requirements.
The complexity of retrofitting varies by machine type. Simple applications, such as forklifts, are relatively straightforward, while more complex machines, such as excavators, require extensive engineering for hydraulic systems and tool functions.
What are the advantages of retrofitting compared to new electric machines?
Retrofitting offers significant cost savings compared to new electric machines, often 40-60% cheaper, while existing operational knowledge and maintenance procedures are largely retained. Moreover, companies can maximize their investments in existing equipment without complete replacement.
An important advantage is the shorter implementation time. While new electric machines often have long delivery times, retrofitting can be realized within 3-6 months. This means faster achievement of sustainability goals and benefiting from lower operating costs sooner.
Retrofitting also offers greater flexibility in customization. Existing machines can be adapted to specific operational needs, without the limitations of standard factory models. This is particularly valuable for companies with unique applications or specific performance requirements.
In addition, retrofitting contributes to the circular economy through the reuse of existing materials and components. This reduces the environmental impact compared to the production of completely new machines.
When is it better to buy new electric machines?
New electric machines are the better choice when existing machines are approaching the end of their lifespan, require extensive repairs, or when factory warranty and standardization take priority over cost savings.
For companies planning a complete fleet renewal, new machines offer benefits such as uniform specifications, standardized maintenance processes, and a full factory warranty. This significantly simplifies training, maintenance, and spare parts management.
New machines are also suitable when the latest technologies are essential. Modern electric machines often feature advanced functions such as regenerative braking, intelligent energy management, and integrated telematics, which are difficult to replicate in retrofit projects.
With high usage intensity, new machines can be advantageous due to optimal energy efficiency and lower maintenance costs during the first few years. The total cost of ownership may then turn out to be more favorable, despite the higher purchase price.
How much does a retrofit cost compared to new electric machines?
Retrofitting typically costs 40-60% of the price of a comparable new electric machine, with the exact costs depending on factors such as machine complexity, desired battery capacity, and required customization. The costs are determined by engineering, battery systems, electric motors, and installation work.
The cost structure of a retrofit comprises various components. The battery system often constitutes the largest cost component, followed by the electric motor and power electronics. Engineering and installation costs vary depending on the complexity of the machine and the necessary modifications to the chassis structure.
For new electric machines, in addition to the purchase price, potential infrastructure costs, training, and adjustments to operational processes must also be taken into account. Retrofitting often utilizes existing facilities and knowledge, resulting in additional savings.
The payback period for retrofitting is typically shorter due to the lower initial investment. Operational savings from lower energy costs and reduced maintenance result in a faster ROI, often within 2-4 years, depending on usage intensity.
How long does the retrofit process for electrical machines take?
The retrofit process takes an average of 3-6 months, from concept to working machine, depending on machine complexity, component availability, and required test procedures. Simple applications can be faster; complex projects may take longer.
The project phases comprise several steps. First, engineering and design take place (4-6 weeks), followed by component production and procurement (6-12 weeks). The actual installation and integration typically take 2-4 weeks, depending on the machine complexity.
Testing and validation constitute a crucial phase that can take 1-2 weeks. This includes functional testing, safety checks, and performance validation to ensure that the retrofitted machine meets all specifications and safety requirements.
Parallel activities can shorten the total lead time. While components are being produced, preparatory work can take place on the machine, such as removing old components and preparing assembly locations.
Which machines are suitable for electrical retrofit?
Machines with relatively new chassis structures, good mechanical condition, and sufficient space for battery systems are best suited for electrical retrofit. Construction machinery, industrial vehicles, and marine applications often offer excellent retrofit opportunities.
Ideal candidates share several common characteristics. The machine must be structurally sound, with a minimum remaining lifespan of 5–10 years. Sufficient space for battery packs and cooling systems is essential, as is accessibility for installation and maintenance.
Specific machine types well-suited for retrofitting include excavators, wheel loaders, forklifts, and industrial generators. These machines typically have clearly defined work patterns and energy requirements, which simplifies engineering.
Less suitable machines are those with extremely high peak power requirements, very limited space, or critical safety certifications that are difficult to maintain after modification. Machines at the end of their lifespan are also often not cost-effective to retrofit.
Whether you choose a retrofit or new electric machines, we help you find the best solution for your specific situation. With our expertise in custom battery systems and industrial electrification, we guide you through the entire process. Please feel free to contact us. contact Contact us for a no-obligation discussion about your electrification options.
