Smart Retrofitting
Modern Performance Without Full Replacement
Older distribution centers and production facilities often rely on aging vertical conveyors, lifts, or incline belts that have reached the end of their reliable life. Frequent breakdowns, limited spare parts, and safety concerns increase downtime and maintenance costs. Retrofitting these systems with modular spiral conveyors offers a smarter, low-risk path to modernization, without the disruption of a full rebuild.
Why Retrofit Instead of Replace Entirely?
Space in modern facilities comes at a premium. Every square meter counts. Traditional incline conveyors occupy extensive floor area, limiting throughput and flexibility. By upgrading to a compact spiral conveyor, you can reduce floor space use by up to 80–90%, freeing valuable space for new processes, SKU storage, or automation zones.
A retrofit allows you to:
- Integrate seamlessly into existing layouts
- Increase capacity and uptime without construction
- Minimize downtime during installation
- Lower total cost of ownership (TCO)
The ROI of a Spiral Retrofit
While a modular spiral conveyor may initially cost more than a welded lift, the return on investment is rapid. Companies that monitor downtime and maintenance report payback within 12–24 months, thanks to:
- High uptime – fewer breakdowns and standardized components
- Energy efficiency – optimized drives and low-friction belts reduce power use
- Scalability – add or remove modules to match operational changes
- Sustainability – reuse existing frames and reduce waste
With real estate costs exceeding €80 per m² per year in many regions, reclaiming even 700–800 m² of space can save tens of thousands of euros annually.
Built for Longevity and Sustainability
Modular spiral conveyors are engineered for circular use. When production heights or layouts change, the modular tracks can be reconfigured or relocated without scrapping the entire structure. This reduces landfill waste, embodied carbon, and material costs, while extending the lifespan of your investment.
Energy-efficient drives and lightweight tracks further reduce your facility’s environmental impact, helping meet sustainability goals without compromising performance.
Seamless Integration for Modern Operations
Whether in food, beverage, parcel, or third-party logistics, modular spirals fit effortlessly into brownfield environments.
Royal Apollo’s design features ensure quick installation and long service life:
- Low-friction slat chains minimize wear on loads and components.
- Reconfigurable tracks adapt to new layouts on site — no welding needed.
- Accessible drive assemblies simplify preventive maintenance.
- Compact, overlapping chain contact allows smooth starts and stops.
These innovations ensure smooth retrofits with minimal production interruption and maximum reliability.
Read more about it in our Whitepaper
This whitepaper explains how retrofitting legacy vertical conveyors with modular spiral systems helps production and distribution facilities modernize without full replacement. Aging equipment causes high downtime costs and space inefficiencies, while modular spirals can reduce downtime, lower total cost of ownership, and free up to 80–90% of floor space. The compact vertical design enables higher capacity within existing buildings, avoiding costly expansions. Modular construction improves uptime, energy efficiency, and maintenance flexibility. Most retrofit projects achieve payback within 12–24 months while supporting long-term sustainability.
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