Integrating IoT With Legacy Equipment: Retrofitting Existing Machines for Smart Operations
- Last Updated: June 5, 2025
Ellie Gabel
- Last Updated: June 5, 2025
The Internet of Things (IoT) benefits a wide range of industrial operations by improving efficiency, enhancing decision-making with data-driven analytics, and enabling predictive maintenance to reduce costs and downtime. However, many companies have existing investments in legacy systems that are not inherently compatible with IoT technologies.
Retrofitting offers a solution by bridging the gap between legacy equipment and modern technology. Explore the necessary considerations and best strategies when retrofitting existing machines for smart operations.
All legacy equipment is not made equal, so it’s crucial to assess existing infrastructure as part of the retrofitting process. Control systems, machines, and sensors that predate IoT innovations are among the many things to examine.
Add to this their varying ages, manufacturers, and automation capabilities, and professionals will get a picture of the many components that go into understanding older systems.
Despite the challenges, retrofitting these systems is crucial for minimizing downtime, maintaining a competitive edge in today’s technology-driven market, and optimizing operational efficiency.
Professionals can attach external sensors to legacy equipment to capture data on vibration, temperature, pressure, flow, and more. IoT-enabled sensors streamline daily operations and support predictive maintenance, allowing workers to address issues before they become too costly or lead to increased downtime.
They also help operations achieve improved environmental standards, reach sustainability goals, and maintain regulatory compliance. Sensors have different use cases, so company leaders should consider which types are most applicable to their operations:
Decision-makers should ensure sensors can handle a warehouse’s environmental conditions. For instance, a company dealing with corrosive materials or extreme temperatures must consider those factors.
Professionals should account for ease of mounting and installation, required power supply for sensor operability, and IoT communication capability.
Existing communication ports — such as an Ethernet or serial communication capability — can extract data via direct connection.
If not, data loggers can temporarily store data retrieved from sensors or equipment outputs. This information can then be uploaded to the IoT platform.
Industrial gateways translate data from the legacy equipment’s protocol — for instance, Modbus, RTU/TCP, or Profibus — to whatever format the IoT platform understands, such as MQTT, HTTPS, or CoAP.
Edge devices or gateways can also help speed up the transition process by preprocessing data before it’s sent to the cloud. There are several ways these devices might do this, including:
Along with data encryption, it is essential that only authorized users and devices can connect to the IoT platform throughout this process for security purposes. Regular security checks also detect and immediately address any vulnerabilities.
Many factors must be considered when retrofitting legacy equipment to make the process as smooth as possible.
While retrofitting for IoT functionality has benefits, it can also lead to security risks. Nearly 100% of security professionals claim securing their organizations’ IoT devices is difficult. The downtime associated with retrofitting equipment can open the door to cybercriminals waiting to exploit system vulnerabilities to secure sensitive data.
Creating a security plan that considers the potential vulnerabilities of new IoT-connected devices is crucial. Everything should have strict authentication measures, and access should be granted to employees on an as-required basis, depending on a worker’s role. Consistent security audits and updates reduce the likelihood of cyberattacks, as does employee training on safety measures, such as using strong passwords and reporting phishing attempts.
IoT devices create a connected network of technology that can communicate with one another. Retrofitting requires a detail-oriented mindset, but leaders should also adopt a holistic approach to manage the interconnected structure of the IoT. This involves ensuring interoperability between retrofitted equipment and other systems, facilitating data exchange with open but still secure protocols, and performing tests to confirm compatibility.
Retrofitting legacy equipment with IoT functionality can help industrial operations optimize performance, enhance efficiency, extend the use of their existing equipment, and gain a competitive advantage in today’s innovative, technology-driven environment.
These implementation strategies and considerations can ensure organizations maximize their investment and reap the rewards of IoT capabilities.
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