Machine Upgrades

Upgrading your EXISTING Machinery: THE SMART FACTORY TRANSITION

When you want to modernise your production line, you don't necessarily need to start from scratch with new modern automation machines. Motion Design specialise in retrofitting, which means taking your reliable, existing machinery and giving it a "digital brain". Our machine upgrade services allow you to retain your existing production lines and mechanical foundations while integrating the latest in AI, Computer Vision, smart Control Systems and sensors. We transform "legacy" equipment into performance, data-driven assets that are faster, safer, and fully traceable, helping you build a smart factory environment while keeping the original mechanical hardware you already trust.

Why Modernise What You Already Have?

Increase Production: By retrofitting your older machinery we can often improve your workflow and speed up production times.
Lower Initial Cost: Upgrading is significantly more cost-effective than buying entirely new systems, often costing only a fraction of a new machine.
Shorter Leadtime: Because we use your existing foundations, it is possible to upgrade quicker than the time it takes waiting for your new machine to arrive.
Sustainable Choice: Reusing heavy mechanical structures reduces waste and is much better for the environment than scrapping perfectly good equipment.
Improve Safety: When upgrading your machinery our team of qualified safety experts can ensure your team is kept safe with the latest technologies.

R&D: PROVE THE CONCEPT BEFORE YOU COMMIT

We know that jumping into a full-scale upgrade can feel like a big step. That’s why we offer a Research & Development (R&D) service. We act as your innovation partners, testing new technologies on your specific products to ensure a full upgrade is the right move for your business. We work with you to help find a solution to your trickiest problems.

Vision Feasibility Studies: Not sure if a camera can detect that tiny defect or handle that specific product packaging? We can set up a trial using our in-house vision systems to prove exactly what is possible before you invest in the final hardware.
Prototype Testing: We can develop small-scale prototypes or "proofs of concept" to show how a system will behave with your unique workflow.
Data-Driven Decisions: Our R&D process gives you real-world results and data. This removes the guesswork, allowing you to see the potential ROI and performance gains before the full-scale retrofit begins.
Creative Problem Solving: If you have a "problem" machine that no off-the-shelf solution can fix, our team thrives on finding the creative engineering answer that others might miss.

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Intelligent Control Systems (The Brain)

We replace outdated PLC and PC controls with modern hardware and high-speed architectures.

Modern Interfaces: Intuitive displays that are easy to use.
Predictive Maintenance: Smart sensors can monitor production throughput, safety, temperature, and cycle data to flag equipment failures before they happen, drastically reducing unplanned downtime.
Energy Efficiency: Measure energy consumption and dynamically adjust production to meet your power usage and environmental targets.
Seamless Integration: We bridge the gap between your factory or production line floor and your office, allowing your upgraded machines to talk directly to your ERP or WMS systems. So you can schedule your production and have all the data when and where you need it.
Motion Design Control systems: and motion control products.

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ADVANCED COMPUTER VISION (THE EYES)

A key pillar of the Smart Factory is the ability for machines to "see" and make decisions in real-time. Motion Design are Machine Vision experts and can apply Vision AI to your systems for enhanced visibility and control.

Automated Quality Control: Find defects or inconsistencies - such as incorrect materials, misaligned labels, imperfections or out of tolerance parts.
Product Identification: Identify a part from a database and label it accordingly.
Precision Handling: Vision systems allow machinery to adapt to different product orientations or shapes, increasing the flexibility of your existing line.
See more about: Machine Vision

Customised Software: The Digital Link

A machine upgrade is only as good as the software running it. We don't believe in "one size fits all" solutions. At Motion Design we have our own in-house software developers and we write customised programs that act as the bridge between your legacy hardware and modern digital tools.

Seamless Integration: Our software allows your old machines to "talk" to your modern office systems, like ERPs or inventory databases, without needing a complete overhaul.
User-Friendly Interfaces: We design custom dashboards for your technicians. Instead of confusing old dials or cryptic codes, your team gets clear, touch-screen visuals that make operating the machine intuitive and simple.
Adaptive Logic: Since we write the code ourselves, we can program the machine to handle new products, different bottle sizes, or varied materials (like high-viscosity liquids) with just a software update.
Data Mastery: We build custom reporting tools that pull the exact data you need - whether it’s hourly yield, energy usage, production wastage, or quality pass rates - and deliver it in a format you can actually use.
Remote or Local Support: If required we can set up remote assistance so we can log in remotely to diagnose issues or perform updates.
Direct Access to Developers: When you call for support, you aren't talking to a call centre - you're talking to the people who wrote the code and engineered the software.

Safety Compliance

In New Zealand, all machinery modifications must align with AS/NZS 4024 safety standards. By upgrading your factory line we ensure your older machines meet these modern requirements, protecting both your workers and your business from liability.

Design Services

We are able to provide mechanical engineering design (CAD) assistance or external review of your design. We can also collaborate on software or control system designs too.

Digital Transformation

Helping businesses to embrace new technologies and digital solutions to improve their operations and customer experience. We can help you on your Industry 4.0 journey.

Industrial Internet of Things (IIoT)

Helping businesses connect their machines, devices, and systems to collect and analyse data for better decision-making.

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