Production modernisation
Production modernisation is the introduction of modern technology, control systems and machinery to optimise production processes. Whatever the size of the plant, timely renewal of capacity keeps competitive products flowing without interruption.
Modernisation of industrial production is a broad concept. It can mean a complete technical re-equipment of the plant, partial replacement of outdated machines with new ones, automation and the introduction of robots into process operations, installation of additional monitoring or remote-control devices at a working station, a change of tooling and working tools to extend the functions of existing equipment, improvement of workflows or the introduction of digital technology. Modernisation is therefore always an individually developed set of measures based on the customer's needs.
What production modernisation includes
Modernisation of operating plants covers a wide range of engineering and technological solutions. We approach it comprehensively, developing a technological plan for the unique tasks of each plant. The scope of modernisation may include:
- Equipment renewal and technical re-equipment. Replacement of physically worn machines and other equipment, and restoration of the service life of existing equipment with replacement of main units.
- Automation and robotization. Introduction of automatic control systems and installation of robotic systems based on industrial and collaborative robots for welding, palletizing, milling and other operations. This removes the human factor, raises the accuracy of operations and stabilises product quality.
- Optimisation of production lines. Re-planning of stations and removal of bottlenecks to reach maximum productivity without building new floor space.
What production modernisation achieves
- Higher production efficiency. Greater output through less downtime and faster cycles.
- Lower costs through optimised consumption of raw materials and energy.
- Better product quality.
- Safer work. Staff are removed from hazardous stations, harmful processes are automated, and the plant meets occupational safety rules and modern environmental standards.
When modernisation is needed
- Equipment is outdated, has used up its service life or has started to work incorrectly;
- You need to re-purpose a process line for new tasks or extend the functions of individual machines;
- You want to raise productivity;
- You have noticed wear on some elements;
- The equipment does not meet safety or environmental requirements;
- Maintenance was carried out in breach of the schedule or not at all.
Technical modernisation becomes relevant when equipment has exhausted its service life, processes no longer meet modern quality standards, or the load on the infrastructure has grown. This applies to plants in all kinds of industries.
Stages of a modernisation project
To carry out modernisation without risk to current operations, we deliver projects in stages with strict control of deadlines. Our approach minimises downtime and gives a predictable result.
Analysis of the current state of production (audit). This is the foundation of the project. Our specialists assess the condition of the equipment, actual efficiency, the organisation of the process and compliance with quality and safety standards. The audit reveals problem areas and hidden reserves.
Technical specification and commercial proposal. Based on the data collected we draw up a technical specification and determine what is more profitable: a turnkey replacement of the line or partial modernisation with upgrades to the existing equipment.
Design. Our specialists develop the technical documentation and the modernisation project.
Selection and supply of equipment. We select the optimal industrial equipment, domestic or imported. Where needed we design and manufacture non-standard tooling for the customer's specific tasks: Teswel has its own experienced design department.
Implementation, installation and commissioning. Integration of the new equipment into the existing infrastructure. Installation, software set-up and commissioning are carried out. The quality of commissioning directly affects the reliability and efficiency of future operation.
Staff training and hand-over. We train engineers, operators and all the staff involved to work with the new systems. After the achieved figures are demonstrated and the acceptance certificates are signed, the project is complete.
What the customer gets
- Optimised resource consumption and lower production costs;
- Higher productivity;
- Systematic production management;
- Safe operation;
- More accurate processes;
- Compliance with current standards and requirements;
- A competitive production;
- High product quality;
- Automated process control;
- A longer service life for the equipment already in the plant.
If the plant does not match modern production technology, norms and standards, if equipment is operated inefficiently and there is room to improve its work and cut energy and material costs, then modernisation is overdue.
Why order modernisation from us
With Teswel you get a reliable partner accountable for the final result.
We take on the whole job, from diagnostics and audit to commissioning and staff training. You do not need to look for separate contractors for design, supply and installation. This lowers risk and speeds up the start of operation. We know how to modernise equipment effectively, extending its service life and functions without major capital expenditure on new imported replacements.
Our experience spans machine building, metallurgy, oil and gas and the food industry. In 15 years our portfolio has grown to more than 200 completed projects.
After the project is complete we do not leave the customer. We provide a warranty on the work and offer technical support and post-warranty service.
FAQ
How much does production modernisation cost?
The cost is determined individually for each project and depends on the size of the plant, the wear of the equipment and the complexity of the technology introduced. The final price is set after the audit and the commercial proposal. We offer flexible forms of cooperation.
How long does modernisation take?
Lead times depend on the scope of work. Partial modernisation (replacing one unit, automating one station) can take from a few days to a month.
Can old equipment be modernised, or must it be replaced?
Yes, in most cases modernising old equipment is the economically justified choice.
How quickly does the investment pay back?
The payback period varies by industry and the scale of investment. Our specialists provide the calculation at the design stage.
For a detailed technical consultation, submit an enquiry on our website.