When industrial machinery appears to have reached the end of its life cycle, the only solution to keep the production line running seems to be replacing the equipment. But what if there were a way to “revitalise” it and continue using it? This solution exists and is called revamping, an approach that CD Automation develops in collaboration with the customer, taking care of every detail.
What does revamping mean and why is it important?
Revamping is the renewal of the electrical and electronic components of industrial machinery. This upgrade does not affect the mechanical parts of the machinery or production plants, since it makes little sense to intervene on components that are still functional and crucial for product quality.
It is also important to note that upgrading control and automation systems is much more cost-effective, as these tend to become obsolete before mechanical components. This electronic renewal can also be applied when acquiring used machinery to be installed on a production line or resold, bringing its performance close to that of new equipment.
Better results, but with the same machinery
Through targeted replacement and refurbishment of electrical panels, PLCs, and obsolete drives, revamping can streamline the production of an industrial plant. By keeping the original machinery, companies can take advantage of the latest generation of industrial automation solutions without needing to retrain personnel.
Revamping applies not only to individual machines but also to entire industrial plants that need to be upgraded or restored to working order.
What are the advantages?
Revamping can deliver all the benefits of new machinery while reducing costs by up to 50% and minimizing machine downtime.
Key advantages include:
- extended service life of machinery;
- increased productivity and plant performance;
- lower energy consumption and improvement in energy efficiency;
- enhanced personnel safety;
- improved product quality and production flexibility;
- reduced production and maintenance costs.
The energy sector
The industrial sector is increasingly interested in and willing to invest in revamping industrial energy plants to modernize and regenerate production facilities. This type of revamping is seen as a strategic opportunity to boost competitiveness on a global scale. Efficiency gains have multiple benefits, including increased competitiveness, reduced environmental impact, and improved brand reputation.
The industrial rise of electricity
A major driver of this trend is the transition from gas heating systems to electric heating systems. Electric systems convert electrical energy into heat for industrial processes, using principles such as electric arcs, resistance heating, dielectric losses, microwaves, infrared radiation, plasma, and lasers.
Electrothermal equipment offers excellent opportunities to increase productivity, energy efficiency, and competitiveness. In many electrothermal processes, heat can be fully exploited without losses, avoiding the classical thermodynamic issue of transferring heat from a higher to a lower temperature source.
What are the benefits of electrical processes?
In addition to energy efficiency, electrical processes provide significant environmental advantages. Electrothermal systems do not produce harmful emissions such as nitrogen oxides, sulfur, or carbon dioxide.
Compared with conventional fossil-fuel heating, electrical processes also offer:
- rapid and uniform heating, precise temperature control, and almost instantaneous start-up and shutdown;
- high-quality end products;
- the ability to create new products, particularly in the chemical and electronics sectors, which are difficult to achieve with conventional heating;
- increased productivity and reduced production costs;
- reliable production processes with simplified control and monitoring;
- automation opportunities for production lines and small-scale industrialized processes;
- safe working conditions for employees.
Why partner with CD Automation?
The electrothermal sector is vast and complex, requiring advanced knowledge of electrical and thermal engineering, as well as materials science. For this reason, when undertaking a revamping project, it is important to rely on experienced partners with decades of multi-sector expertise. CD Automation has been manufacturing intelligent electrical power control systems for over thirty years, supporting applications such as plastics and packaging machines, furnaces for heat treatment of glass and metals, the food industry, and renewable and traditional energy systems, including oil and gas.
Revamping: the importance of product reliability
CD Automation produces top-quality thyristor power controllers, supported internationally by a network of branches and leading partners in the industrial temperature control sector. These products help reduce:
- power line disturbances,
- electrical cable heating,
- energy losses.
The control system developed by CD Automation keeps the power factor close to 1, avoiding unnecessary energy costs.
The company also focuses on compact designs by integrating multiple functions into a single multi-channel unit, meeting the demands for compactness, competitiveness, and sustainability.
The ideal unit for every need
CD Automation has established a centre of expertise to support partners in electrifying applications, reducing consumption and complexity, and improving power quality in thermal processes.
Companies can draw on a wide range of products, including SCR units such as:
- REVO S – High-performance, reliable, flexible and compact solid state relays, available from 3.5 to 800A.
- REVEX – Universal power regulators with flexible configuration and high performance.
- REVO C – Universal single/two/three-phase power controller from 30 to 2100A.
- REVO PN and REVO PC – Multi-channel power controllers for intelligent management of electrical loads.
Are you planning to update your heating systems or undertake a revamping project and need the expert advice of a professional? Contact us to schedule a free consultation with one of our specialists. You will receive tailored proposals to optimise your systems, extend their lifespan, and minimise downtime.
