Retrofit-vs-replace analysis and phased modernization of an aging brick production line without stopping the plant.
A brick producer was running a line that had been in service for decades. Downtime was climbing, spare parts were getting harder to source, and the owners faced a capital decision: keep patching, retrofit, or build new. A full replacement was priced far beyond what the market position justified.
We ran a retrofit-vs-replace analysis with a full cost model for each scenario, then engineered a phased modernization plan: new handling automation, drives and controls on the existing mechanical backbone. Our team developed the URS, sourced suppliers through a vendor-neutral RFQ, and scheduled every installation phase around production — the plant never stopped shipping.
The retrofit was completed in 2022 at roughly a third of the cost of a new line. Unplanned downtime dropped by half within the first quarter, and the added automation removed the two most labor-intensive stations from the line — the payback period came in under two years.
