Retrofitting in intralogistics: Why modernization is the decisive competitive factor today

Intralogistics systems are complex structures whose performance depends significantly on the interaction of their components. What holds true in mechanics – "a chain is only as strong as its weakest link" – applies particularly to automated storage systems. However, while steel structures can last for decades, electronic components and software age considerably faster. The risk of malfunctions, failures, and costly downtime increases. Furthermore, energy efficiency and safety standards often no longer meet current requirements.
The result: system availability decreases and maintenance costs rise. This inevitably brings the question of modernization into focus.

Retrofit: minimal intervention, maximum impact

This is where LTW Intralogistics comes in. As the interface between production and shipping, intralogistics is business-critical for many companies. Retrofit projects therefore aim to bring existing systems back to a level comparable to that of a new system – with minimal disruption to ongoing operations.

More than 600 retrofit projects worldwide: experience that pays off.

With over 600 successfully completed retrofit projects worldwide, LTW possesses extensive experience from which its customers benefit. The company provides comprehensive support to its clients: from consulting and engineering to the conversion, recommissioning, and after-sales service. In many cases, a modernized system subsequently achieves the availability of a new system.
The practical example of Salinen AG demonstrates how precisely and effectively planning is carried out: Thanks to a forward-looking conversion concept, the conveyor technology was even able to go into operation earlier than originally calculated. "The plan worked perfectly," confirms Andreas Neubacher, Project Manager Engineering.

Customer focus as a guiding principle

No two retrofits are alike. LTW analyzes each system in detail, identifies weaknesses, and develops customized concepts – always with a focus on technology and cost-effectiveness. A particular advantage is that many modernizations can be implemented during ongoing operations or in stages. This keeps downtime to a minimum, makes investments predictable, and minimizes disruption to operations.
Wolf ButterBack KG illustrates the impact this can have: Despite extremely low temperatures, a third-party system was successfully modernized and brought up to the technological standard of the latest LTW system. "That's how it should be," summarizes Managing Director Ernst Stengel.

More power, less cost: The advantages of retrofitting

Modernization by LTW contributes to several objectives:

• Higher system availability – regardless of the original manufacturer
• Reduced maintenance costs
• Guaranteed spare parts and support capability
• Updated security and technology standards
• Significant energy savings and improved CO₂ balance

This makes retrofitting a key lever for making existing systems sustainably fit for the coming years – or decades.

Software Retrofit: The “Open Heart Surgery”

A particular challenge in the modernization process is the replacement of the IT infrastructure. Legacy systems quickly reach their functional limits, while at the same time, operational interruptions must be avoided. LTW addresses this challenge with in-depth expertise and a proprietary digital twin technology. This technology allows the entire software migration to be simulated and extensively tested in advance. The new system only goes live after successful testing.

Conclusion: Retrofitting as a strategic success factor

In an era where supply chains must become more resilient, efficient, and sustainable, retrofit solutions are gaining significant importance. Modernizing existing systems is not only more cost-effective than new construction, but also provides planning certainty, increases availability, and brings systems up to the latest technological standards.
With decades of experience, comprehensive service offerings, and a consistently customer-focused approach, LTW Intralogistics positions itself as a reliable partner for all companies seeking to future-proof their intralogistics.

Konrad Wolfenstein

I would be happy to serve as your personal advisor.

contact me under Wolfenstein ∂ Xpert.digital

call me under +49 89 674 804 (Munich)

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