Shuttle racking warehouse with a yellow shuttle in a pallet lane
Shuttle racking retrofit for all brands

Keep Your Racking. Upgrade the Technology.

Aging shuttle racking does not always need to be replaced. Through retrofit, the control system, communication, and software of any shuttle brand can be upgraded without dismantling the existing installation.

Technical consultation is available to evaluate your system.

Consult Our Engineers Learn About Our Approach

Still Running, but Increasingly Difficult to Maintain?

The structure is still sound, yet minor faults take longer to resolve. In most cases, the cause lies in one of these four areas.

Obsolete Controller

The original PLC is hard to replace, and fewer people understand it.

Spare Parts Hard to Source

Components are no longer manufactured. A single failure can stop a lane for days.

Battery & Charger Issues

Batteries degrade quickly, shuttles stop to charge more often, and replacement costs keep rising.

High Replacement Cost

Significant CAPEX, lengthy approvals, and downtime that operations cannot easily absorb.

In many cases, the racking does not need to be replaced.

How retrofit works

Retrofit, Not Full Replacement

We keep what still performs and upgrade what holds you back.

Current System

RackingInstalled
ShuttleInstalled
Old controllerObsolete
Old communicationObsolete

After Retrofit

Existing rackingRetained
Existing / upgraded shuttleRetained
New control systemNew
Modern communicationNew

Preserve your mechanical investment. Modernize the technology.

Same Racking, a New Way of Working

Before

Legacy Shuttle System

  • Aging PLC that is hard to maintain
  • Replacement parts hard to source
  • Old communication
  • Faults difficult to trace
  • Operates in isolation from other systems
After

Modern Shuttle System

  • Modern, maintainable PLC / controller
  • New electrical components
  • Modern communication
  • Remote diagnostics for faster response
  • Real-time condition monitoring

Retrofit or Full Replacement?

A concise comparison to help engineering, finance, and procurement teams weigh the options.

AspectFull ReplacementRetrofit
Existing racking✕Replaced✓Retained
Mechanical structure✕Replaced✓Retained
Control systemNewUpgraded
SoftwareNewUpgraded / integrated
Installation timeLongerPotentially shorter
CAPEXHigherPotentially lower
Warehouse disruptionGreaterReduced
System lifespanNew systemExtended

A retrofit can significantly reduce capital expenditure while extending the service life of your racking.

Actual savings depend on the condition and architecture of the system. We confirm the figures in our proposal after a site survey.

For All Shuttle Brands

Every installation is different, so we always start from actual site conditions, regardless of brand or system age.

Multi-Brand, One Engineering Team

Assessment and retrofit of shuttle racking from various manufacturers, tailored to the system architecture and available interfaces.

  • PLC & controller replacement
  • Electrical panel retrofit
  • Shuttle communication
  • Battery & charger
  • Sensors & safety system
  • HMI
  • Remote control system
  • Troubleshooting
  • Preventive maintenance

Our Retrofit Services

One team for control systems, electrical, software, and after-sales support.

Control System Retrofit

Modernization of PLCs, controllers, electrical panels, and control architecture for easier maintenance by your team.

Shuttle Upgrade

Upgrades to shuttle units, communication systems, and operating software.

Battery & Charging

Battery replacement, charging systems, and power management for more reliable shuttle operation.

Communication

Modern wireless communication between shuttles, controllers, and warehouse systems.

Service & Maintenance

Troubleshooting, preventive maintenance, and replacement of obsolete components.

From Assessment to Modernization

Each stage has clear deliverables. You receive a written diagnosis and proposal before deciding to proceed.

  1. 01

    Site Survey

    We review the racking, shuttles, control system, electrical, and communication together with your operations team.

  2. 02

    System Diagnosis

    Obsolete components, failure points, and upgrade opportunities are mapped in a written report.

  3. 03

    Retrofit Proposal

    The most practical solution for your requirements, including scope of work and cost estimate.

  4. 04

    Engineering & Testing

    Hardware, software, and control systems are designed and tested before installation.

  5. 05

    Installation

    Scheduled with your team to keep downtime under control.

  6. 06

    Commissioning

    System testing and operator training until your team can operate independently.

  7. 07

    After-Sales Support

    Maintenance, troubleshooting, and further development after project completion.

  8. →

    Initial Survey

    A starting point to assess your system, with no obligation to proceed.

    Contact Us

Our Approach

We are an engineering team focused on warehouse automation retrofit and integration.

Retrofit & Automation Integration Specialists

Extending the service life of the systems you already own.

PLC & Electrical Retrofit Expertise

Competent in industrial control systems and electrical panels.

After-Sales Engineering Support

Continued support after handover.

Our Field Experience

Selected shuttle racking projects we have undertaken.

  • Mayora
  • Wilmar

These projects can serve as a reference for warehouses with similar systems.

Retrofit Consultation

Whatever the brand of your shuttle racking, our engineers can provide an initial assessment based on the following information.

  • Shuttle racking brand
  • System age
  • Shuttle model
  • Current issues
  • Photos of the control panel
  • Photos of the shuttle
  • Installed PLC / controller details

Any unavailable data can be completed during the site survey.

Consultation Form

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