Controls and Electrical Retrofits
Mechanical restoration is often most effective when aging electrical and controls systems are addressed at the same time. Obsolete PLCs, unsupported drives, failing HMIs, and outdated electrical cabinets can continue to create downtime even after the mechanical systems have been rebuilt.
Electrical retrofit capabilities may include:
- Obsolete PLC replacement
- HMI and touchscreen modernization
- AC and DC drive upgrades
- Servo and motion-control upgrades
- Motor-control replacement
- Control-panel modernization
- Electrical cabinet replacement
- Safety-system upgrades
- Sensor and feedback-device replacement
- Network and communication upgrades
- Improved machine diagnostics
- Updated electrical drawings and software backups
Learn more about our corrugated machine controls and PLC upgrades.
Flexo Folder Gluer Rebuilds and Upgrades
Flexo folder gluers contain multiple coordinated sections, and wear in one area can affect feeding, printing, slotting, folding, gluing, and finished-box quality.
Flexo folder gluer rebuild and retrofit projects may include:
- Feeder-section restoration
- Print-section mechanical repairs
- Roller and cylinder refurbishment
- Slotter and scoring-system rebuilds
- Folding-rail and belt improvements
- Gluing-system upgrades
- Drive and controls modernization
- PLC and HMI replacement
- Safety-system improvements
- Registration and synchronization upgrades
- Pneumatic-system modernization
- Production and changeover improvements
Visit our flexo folder gluer service and upgrades page for additional support options.
Rotary Die Cutter Rebuilds and Retrofits
Rotary die cutters require accurate feeding, registration, cutting, creasing, and material transfer. Mechanical wear or outdated controls can affect product quality and increase waste.
Potential rotary die cutter projects may include:
- Feeder and transfer-system repairs
- Cylinder and roller refurbishment
- Bearing and shaft replacement
- Drive-system repairs
- Gap and pressure restoration
- Register-control improvements
- PLC and HMI modernization
- Drive and servo upgrades
- Safety-system improvements
- Electrical panel replacement
- Production diagnostics and testing
For dedicated repair and maintenance support, learn more about our Rotary Die Cutter Service and Repair.
Corrugator and Converting Equipment Modernization
manroland Goss can evaluate a range of corrugated converting and packaging machinery, including:
- Flexo folder gluers
- Rotary die cutters
- Folder gluers
- Stitchers
- Stackers
- Bundlers
- Palletizers
- Laminators
- Feeders
- Conveyors
- Finishing systems
- Material-handling equipment
Support depends on the machine, manufacturer, condition, available documentation, and project scope.
Mechanical Retrofits
A mechanical retrofit can address recurring wear, alignment problems, difficult setup, or outdated machine components without requiring complete equipment replacement.
Mechanical retrofit opportunities may include:
- Improved feeder components
- Updated rollers and bearings
- Shaft and gear replacement
- Belt and chain-drive improvements
- Pneumatic-system upgrades
- Alignment and register improvements
- Updated guarding and access
- Improved lubrication systems
- Faster setup and adjustment mechanisms
- Replacement of difficult-to-source components
Our mechanical specialists can help identify which improvements are likely to provide the greatest operational benefit.
Automation and Productivity Improvements
A rebuild or retrofit can also improve how the machine operates, not just replace worn components.
Potential productivity improvements include:
- Automatic positioning
- Recipe-based settings
- Faster changeovers
- Improved machine sequencing
- Better section synchronization
- Reduced manual adjustment
- Enhanced alarms and fault diagnostics
- Production counters and performance tracking
- Remote diagnostic access
- Improved integration between machine sections
These improvements are engineered around the equipment and production process rather than applied as a generic retrofit package.
Safety-System Improvements
Older equipment may rely on obsolete safety components or systems that no longer support current operating requirements.
Safety-related upgrades may include:
- Emergency-stop circuit modernization
- Safety PLC upgrades
- Safety-relay replacement
- Guard-switch integration
- Light-curtain integration
- Improved safety-zone controls
- Updated electrical documentation
- Safety-system testing and validation
Recommendations depend on the equipment, application, and agreed project scope.
Rebuild or Replace?
Replacing an entire machine may be the right decision in some situations. In others, a strategic rebuild or retrofit can extend equipment life while avoiding the cost, lead time, and disruption associated with complete replacement.
A rebuild may be worth evaluating when:
- The machine structure remains sound
- Replacement equipment has a long lead time
- Controls or drives are obsolete
- Mechanical wear is concentrated in specific sections
- Replacement parts are difficult to source
- Production needs have changed
- Reliability has declined
- Setup and changeover times are excessive
- A complete replacement is not currently practical
Our team can help evaluate the equipment and identify whether repair, rebuilding, modernization, or replacement is the most practical path.
Our Rebuild and Retrofit Process
1. Equipment Assessment
We evaluate the machine’s mechanical condition, electrical systems, controls, safety systems, and production challenges.
2. Project Prioritization
Our team identifies critical repairs, obsolescence risks, and improvement opportunities.
3. Engineered Scope
We develop a customized project plan covering mechanical, electrical, controls, parts, installation, and commissioning.
4. Preparation and Fabrication
Required engineering, programming, panel construction, parts sourcing, and component preparation are completed in advance.
5. Installation and Rebuild Work
The agreed mechanical and electrical work is completed on-site or through a combination of shop and field services.
6. Testing and Commissioning
The equipment is tested, adjusted, and commissioned based on the project scope.
7. Documentation and Support
Updated drawings, software backups, training, and ongoing support may be included as required.
Benefits of Rebuilding Corrugated Equipment
A well-planned rebuild or retrofit may help manufacturers:
- Reduce unplanned downtime
- Improve production consistency
- Extend equipment life
- Replace obsolete components
- Improve troubleshooting
- Reduce dependence on unsupported technology
- Improve operator controls
- Increase maintainability
- Improve machine safety
- Reduce waste
- Support future production requirements
- Delay or avoid full equipment replacement
Why Choose manroland Goss?
manroland Goss brings decades of experience supporting complex production machinery, mechanical systems, controls, drives, and engineered upgrades.
Customers rely on our team for:
- Mechanical and electrical expertise from one source
- Customized rebuild and retrofit solutions
- Support for equipment from multiple manufacturers
- Experienced engineering and controls specialists
- Obsolescence planning
- Parts and component sourcing
- On-site and remote support
- Updated documentation and software backups
- Solutions focused on reliability and equipment life
Frequently Asked Questions
What types of corrugated equipment can be rebuilt?
We can evaluate flexo folder gluers, rotary die cutters, folder gluers, stitchers, stackers, palletizers, laminators, conveyors, feeders, and other corrugated converting or packaging equipment.
Do you rebuild equipment from other manufacturers?
Yes. manroland Goss supports equipment from multiple manufacturers. The available scope depends on the machine, condition, documentation, and required work.
Can mechanical and controls upgrades be completed together?
Yes. Combining mechanical rebuilding with controls modernization can address multiple reliability and obsolescence concerns within one coordinated project.
Can you rebuild only one machine section?
Yes. Projects can focus on a specific section, component group, or system when a complete machine rebuild is not necessary.
Can rebuild work be completed during a planned shutdown?
Yes. Many projects are planned around scheduled shutdowns. Larger projects may require advance engineering, fabrication, programming, and parts preparation.
Will updated drawings and software backups be provided?
Documentation can be included in the project scope. The exact deliverables depend on the existing equipment and the extent of the work.
How do we know whether rebuilding is worth the investment?
An equipment assessment can help identify the machine’s condition, major risks, estimated scope, and likely operational benefits.
Automatic cardboard box packing and tape sealing machine
Request a Corrugated Equipment Assessment
Whether you are dealing with recurring mechanical failures, obsolete controls, production limitations, or an aging machine that is becoming difficult to maintain, manroland Goss can help evaluate the next step.
Provide the equipment manufacturer, model, age, current problems, and production requirements when contacting us.
Contact Our Corrugated Equipment Team
