When aging equipment starts holding your production back, a full system replacement isn’t always necessary—or cost-effective. Retrofitting offers a smart alternative by integrating new technology into your existing systems, extending equipment life while improving accuracy, reliability, and efficiency. That’s exactly what Gerhart delivered in this recent sugar batching retrofit project.
The Challenge: Modernize Without Rebuilding
A long-time customer approached Gerhart with the need to automate and improve batching accuracy for a 5,000 lb. sugar hopper. Rather than replacing the entire system, the goal was to retrofit the hopper with modern weighing and control capabilities while minimizing downtime and structural changes.
The Retrofit Solution
Gerhart’s team designed, programmed, and installed a custom Loss-in-Weight Batching System using retrofit weighing assemblies built around the customer’s existing K-Tron SFT transducers. Standard off-the-shelf load cells were integrated into Gerhart-fabricated, wash-down ready assemblies—all without requiring modifications to the existing hopper or support structure.
At the core of the solution was a Programmable 920i Indicator, customized in-house by Gerhart’s engineers with a tailored batching program. The system enabled precise control of the rotary valve located at the base of the hopper, allowing sugar to be dispensed in two-speed increments for accurate batch targeting.
The Result: Reliable, Repeatable, Efficient
With a simple interface, operators can now enter a desired batch weight and press a button. The system takes care of the rest—delivering consistent, repeatable results that maintain recipe integrity and dramatically increase production efficiency.
Why Retrofitting Matters
Retrofitting is one of the most cost-effective strategies for modernizing industrial equipment. Instead of scrapping what still works, retrofits allow facilities to:
- Increase process accuracy with modern instrumentation
- Improve safety and compliance with updated controls and enclosures
- Reduce downtime and installation costs by preserving infrastructure
- Enhance scalability and automation without starting from scratch
Gerhart brings deep engineering expertise and fabrication capabilities to every retrofit. Whether it’s a hopper, batching line, or full material handling system, we design solutions that fit your operation—not the other way around.
Looking to upgrade without replacing?
Contact Gerhart to discuss a retrofit solution customized to your needs.