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Upgrades & Retrofits – Tascomp
Services · Implementation & Modernisation

UPGRADES & RETROFITS

Modernise Without Starting Over

Your existing equipment doesn't necessarily need replacing — it needs a system that keeps up with it. We upgrade and retrofit control and monitoring systems so they carry on doing the job, just better.

Tascomp's engineers assess what you already have, then modernise the parts that are holding you back — hardware, software, or both — without disrupting the operation you rely on every day. By retaining the equipment that still works and upgrading the areas that need improvement, you get a modern operation without the cost and disruption of a complete replacement.

Signs It's Time

IS YOUR SYSTEM DUE AN UPGRADE?

A few signs worth paying attention to.

Before
Legacy System
  • Ageing hardware nobody makes parts for anymore
  • Software that's no longer supported or updated
  • Manual workarounds patched on over the years
  • Little to no remote visibility
After
Upgraded System
  • Modern, supported hardware and software
  • Fewer manual workarounds, more automation
  • Real-time visibility from anywhere
  • Extended equipment life, without full replacement
The Risk Of Waiting

WHAT AN AGEING SYSTEM COSTS YOU

The longer an outdated system stays in place, the more these risks compound.

Unplanned Downtime
Obsolete parts and undocumented workarounds make failures harder to predict and fix.
Cost of waiting ££££
No Vendor Support
Manufacturers stop supporting old hardware and software, leaving you to fend for yourself.
Cost of waiting ££££
Disappearing Knowledge
Fewer engineers understand how to maintain systems built decades ago.
Cost of waiting ££££
Rising Running Costs
Sourcing spares and keeping ageing equipment limping along gets more expensive every year.
Cost of waiting ££££
Our Approach

WHAT WE UPGRADE

A retrofit can be as straightforward or comprehensive as the project needs — from a single upgraded panel to a fully integrated, connected system.

PLC & Control System Upgrades
Replacing obsolete PLCs, drives and I/O with modern, supported equivalents, and developing new control logic where the process itself needs improving.
HMI & SCADA Upgrades
Clearer machine visualisation, improved alarm management and easier day-to-day use, without retraining your whole team from scratch.
Machine Monitoring & Visibility
Adding data collection and OEE, alarm and event monitoring to existing equipment, without interfering with its core control system.
System Integration
Connecting equipment to MES, ERP, databases and other production systems, so it becomes part of a wider, joined-up operation.
Data & Connectivity
Adding remote access and reporting that your legacy system never had.
Ongoing Support
Direct, UK-based support for the upgraded system, for the long term.
How We Work

OUR APPROACH TO AN UPGRADE

Every retrofit starts the same thorough way, whatever the scope.

01
Full System Assessment
Understanding exactly what your current system does, and what's worth keeping.
02
Upgrade Plan
Designing a modernisation plan built around your process and budget, not a generic template.
03
Data & Process Migration
Carrying over the historical data and logic that's still valuable to your operation.
Discovery & System Investigation
Connected Factory

TURN OLD MACHINES INTO DATA SOURCES

A machine may have been installed many years ago, but it can still hold valuable production information. By connecting to its PLC, controls or available signals, we can capture:

Machine status Production quantities Cycle times Downtime Alarms Process values Product information Energy consumption Operator activity

That information can then be made available through dashboards, reports, databases, MES or ERP systems — giving you greater visibility from existing equipment, without necessarily replacing the machine itself.

What is the machine doing? How much is it producing? When & why is it stopped? How is it performing against target?
Close-up of an I/O panel with the door open, showing terminals and wiring
Modernise At Your Pace

START SMALL, SCALE OVER TIME

You don't have to modernise everything at once. A retrofit can begin with a single problem and develop from there — spreading investment over time rather than committing to it all up front.

Monitor
Connect
Analyse
Improve
Control
Automate

A manufacturer may start by simply monitoring machine performance. Once that data is flowing, reporting, traceability or system integration often follow — before eventually upgrading controls or automating parts of the process. Documentation may be incomplete and equipment may have been modified over the years, but our engineers work with what's already in place to find the most practical route forward, retaining existing infrastructure rather than replacing it unnecessarily.

A Growing Risk

STILL RUNNING OLD VERSIONS?

Older Windows versions bring risks that go well beyond a dated interface.

Cybersecurity Concerns
No Security Patches
Unsupported Windows versions no longer receive updates, leaving known vulnerabilities wide open.
Ransomware & Malware Exposure
Older systems are a common target, since exploits for outdated Windows are well documented.
Outdated Authentication
Legacy systems often lack the security controls expected on today's networks.
Performance Issues
Slower, Less Reliable
Ageing hardware paired with outdated software means slower boot times and more frequent crashes.
Compatibility & Driver Issues
Older peripherals and software increasingly won't run on new Windows versions at all.
Increased Downtime
Performance issues compound over time, leading to more frequent unplanned stops.

Interested In Learning More?

The aim of a retrofit isn't to make old equipment look new — it's to extend the useful life of assets that still provide value, while adding the technology needed to make them more productive, connected and supportable. Get in touch to talk through what's holding your current system back — we'll help you work out what an upgrade or retrofit could look like for your operation.

Discuss Your Project