Screw compressors are backbone equipment in modern industry, but aging units can lose efficiency, reliability, and increase operating expenses. Proactive retrofits—upgrading technology and components—can extend machine life and reduce costs. Below are five indicators that signal when it’s time for a retrofit.

1. Rising Energy Costs & Decreased Efficiency

A sudden uptick in electricity bills without increased production volume often stems from compressor inefficiencies. Internal wear, airflow restrictions, and outdated control systems contribute to declining performance . Retrofitting with modern electronics like VSDs or optimizing compressor control can restore efficiency and cut energy use by 20–35%.

2. Frequent Breakdowns & Unplanned Maintenance

Is your screw compressor requiring service more than once every few months? Growing maintenance frequency—such as frequent discharge valve failures or bearing replacements—is a classic sign of aging hardware . A retrofit can include replacing critical components, refreshing control systems, and avoiding costly downtime.

3. Excessive Vibration, Noise & Heat

Unusual vibration or elevated operating temperature often points to mechanical misalignment, worn rotors, or deteriorating seals . These symptoms reduce bearing and seal life. A retrofit targeting cooler upgrades, better alignment, or enhanced isolation can significantly reduce heat and vibration, enhancing system reliability.

4. Outdated Control Systems & Lack of Automation

If your compressor uses an old analog sequencer, lacks remote access, or cannot integrate with your plant SCADA/DCS, that’s a big red flag. After a decade, control system hardware becomes obsolete . Modern retrofits replace these with smart controllers, real-time monitoring, and connectivity, enabling load-following, condition-based maintenance, and predictive analytics—delivering substantial energy and performance gains.

5. Spare Parts Scarcity & Long Lead Times

Obsolete compressor models often suffer from dwindling spare parts availability and extended delivery times. When repair waits stretch due to part shortages, production stops turn costly. Retrofit options may include updating to current field-replaceable modules and standardized components, ensuring parts availability and minimizing inventory.

Summary Table

Why RETROFIT IS SMARTER THAN REPLACE

• Cost-effective: Retrofits typically cost 30–60% less than buying new units and deliver quick ROI through energy savings

• Extended lifespan: Add 5–10 years of reliable service to your compressor with critical upgrades.

• Reduced downtime: Modern components and controls mean fewer unplanned stops.

• Sustainable operations: Improved efficiency reduces CO₂ footprint and aligns with ESG goals.

KEEPWIN Retrofit Solutions

KEEPWIN offers tailored retrofit packages covering:

• VSD motor drive upgrades

• Smart sequencing controllers compatible with SCADA

• Heat exchanger & cooler refurbishment

• Seal, bearing, and rotor rebuild kits

• Remote monitoring & telemetry add-ons

Our modular retrofit kits help B2B customers extend service life, reduce energy and maintenance costs, and elevate system reliability—without a full compressor replacement.

Signs like rising energy bills, frequent repairs, excessive heat, outdated controls, and parts shortages are clear warnings that your screw compressor is due for a retrofit. Addressing these issues proactively enables significant efficiency upgrades, operational reliability, and cost savings.

👉 Ready to evaluate your screw compressor? Talk to KEEPWIN engineering experts today for a free retrofit assessment and actionable improvement plan.