Retrofitting Legacy Production Lines with Custom Conveyors

Production environments must deal with product changes, packaging, and throughput requirements. Older facilities, however, often struggle to accommodate newer equipment and layouts. This makes retrofitting essential for maintaining operational relevance for an industry.

Many manufacturers opt for custom-built conveyors to modernize their operations without a complete overhaul. These conveyors are tailored to address limitations in aging infrastructure, optimize process flow, and maximize available space.

Assessing Existing Layouts for Upgrade Potential

Every existing production line has physical and operational constraints.

A retrofit starts by mapping these limitations:

• Identify bottlenecks in material transfer or equipment transitions.
• Note outdated machinery that hinders performance.
• Review spatial restrictions, such as low ceilings or fixed structural elements.
• Examine current flow paths and manual touchpoints.

Retrofitting isn’t about replacing everything; it’s about designing conveyors that fit within the limits and resolve inefficiencies.

When Retractable Conveyors Offer a Cleaner Fit

Retrofitting often means working around shared spaces or intersecting operations. This is where retractable conveyor units add value.

They slide in and out of place, providing temporary access where fixed equipment would block movement. Ideal for washdown zones, manual inspection points, or dual-use areas, these conveyors minimize unnecessary disassembly and layout conflicts.

Retractable units also minimize damage risks when forklifts or maintenance crews need occasional access through the line.

Using ARB Technology in Constrained Spaces

Traditional layouts rarely align with today’s automation standards. When products require smart orientation, merging, or sorting in tight areas, ARB conveyors (Activated Roller Belt) bring flexibility.

ARB solutions reduce dependency on manual sorting and realign flow without excessive line length. The rollers embedded into the belt surface move items in every direction, all within the footprint of a standard transfer section.

These are especially useful in packaging retrofits where multiple SKUs must enter a shared path or diverge toward different processes.

Minimizing Downtime During Integration

Downtime remains a critical concern during any upgrade; projects must integrate new conveyors while maintaining ongoing operations.

Follow the practices below:

• Opt for modular frame construction for fast swap-outs.
• Choose weekend or off-shift installation timelines.
• Select pre-assembled units that are tested before arriving on-site.
• Use simulation software to preview integration paths.

With good planning, custom conveyor retrofits can be done with minimal disruption to production.

Flat Belt Conveyor as a Modular Entry Point

One of the easiest starting points for retrofits is the flat belt conveyor, which supports a wide range of uses across various industries.

Flat belts work well for:

• Cleanroom or food-safe environments
• Product inspection stations
• Light-to-medium weight product transfer
• Temporary integration until full modernization

They can be outfitted with side guides, stoppers, or diverters to enhance their functionality without increasing their footprint.

Why Custom Retrofits Provide Better Alignment than Standard Replacements

Legacy line upgrades are rarely uniform, and standard products may fall short of meeting safety or layout requirements.

CONOVEY offers retrofit-ready designs, whether that involves a retractable conveyor, ARB Conveyors, or a modular flat belt conveyor. Each solution is CAD-modelled and engineered to operate effectively in real-world conditions.

Retrofitting isn’t about compromise, it’s about making smart, measurable changes. We deliver custom-built conveyors that restore performance to legacy lines without costly overhauls.

Contact CONOVEY to start your project site upgrade today.