Efficient retrofit modernization of ventilation systems with innovative technology
Modernize old systems and reduce operating costs
Retrofitting is the retrofitting or conversion of refrigeration, air conditioning or ventilation systems.
We modernise your old systems and ensure noticeable energy savings. By replacing old fans with energy-efficient ebm-papst EC fans, we reduce your operating costs.
One important aspect is that almost every retrofit project is eligible for funding. Germany provides funding that is not being utilised.
It is therefore all the more worthwhile to subject your system to an energy-efficient refurbishment.
The systems to be modernised include air conditioning systems, refrigeration systems, chillers, cooling towers and many other systems in which fans play a crucial role.
We offer you everything from a single source:
1. initial assessment and advice
We provide you with an initial assessment with the help of old device cards, as well as on-site advice and inspection of the systems.
2. measurement
For effective and efficient energy optimisation, we measure the actual electrical power and air performance.
3. interpretation
We use the data to design the required fans or a fan wall. If required, including the necessary peripherals such as sheet metal, canvas supports and switch cabinets including control and regulation technology. With or without data acquisition and monitoring, depending on your requirements.
4. calculation of ROI
We calculate the return on investment for you.
5. offer preparation
We will provide you with a quote with or without conversion.
6. commissioning and documentation
We take care of commissioning, including preparing the documentation and providing the inspection documents.
We offer you everything from a single source:
Control system modernization (PLC, HMI, remote maintenance)
Upgrading outdated control systems with modern PLC solutions and operating panels. Implementation of remote maintenance concepts for efficient maintenance.
– Migration to the latest automation hardware
– Modernization of user interfaces (HMI)
– Connection to higher-level control systems
Drive technology (motors, frequency converters)
Energy-efficient conversion to modern drive solutions with higher efficiencies and optimized control technology.
– IE3/IE4 efficient motor solutions
– Frequency inverters for optimum speed control
– Servo drives for precise positioning
Safety technology (safety control, emergency stop)
Adaptation to current safety standards in accordance with the Machinery Directive and standards such as EN ISO 13849.
– Modernization of emergency stop systems
– Safety controllers with PL d/e
– Electro-sensitive protective equipment
Documentation & CE
Complete documentation in accordance with the Machinery Directive and CE Declaration of Conformity for modernized systems.
– Technical documentation in accordance with current standards
– Carrying out risk assessments
– Drawing up the declaration of conformity
Project planning & commissioning
Complete support from conception to commissioning, including staff training.
– Individual project planning
– Implementation by experienced technicians
– Functional testing and acceptance on site
Case Studies
Field reports and success stories from the field
When Dieter Hildebrandt from Breuell & Hilgenfeldt takes on a retrofit
, his customers no longer have to worry. He takes care of the
thinking and planning.
Mr Hildebrandt, you have completed over 100 projects, making you an experienced
Retrofit specialist. How do you approach these projects?
Before a retrofit can be implemented, planning and design are required.
We are on hand to provide our customers with advice and support. This means that we assist them in compiling performance data, develop possible concepts and provide examples — including a rough cost overview. We ask ourselves: What is the purpose of the system? How should it be operated? And how can we regulate it?
Do you then also see the retrofit through to the end?
Yes, of course. We plan the entire process and split it up if projects cannot be completed within a year.
Then we first retrofit the fan, program the operating point in the new fans and, in a second step, convert the electrical system.
In consultation with ebm-papst, we select the right fan and the appropriate motor.
We organise dismantling, assembly and electrical integration into the system. To be able to compare how efficiency has improved, we take measurements before and after the conversion.
We organise dismantling, assembly and electrical integration into the system.
In order to be able to compare how efficiency has improved, we take measurements before and after the conversion.
‘As soon as the plant is 10 to 15 years old, it pays off.’
DIETER HILDEBRANDT, SALES MANAGER AT BREUELL & HILGENFELDT
…
Further case studies
We will be happy to answer any questions you may have and look forward to hearing from you.
You can reach us Monday to Thursday from 8 a.m. to 5 p.m. and Friday from 8 a.m. to 2 p.m.
Retrofit fans – the key to greater energy efficiency
Fans play a key role in the retrofitting of ventilation systems because they directly influence energy efficiency, air quality and operating costs.
Here are the most important aspects:
1. Energy efficiency
- Old systems often use outdated centrifugal fans with low efficiency.
- Modern fans (e.g. EC fans with electronically commutated motors) achieve significantly higher efficiency levels and considerably reduce power consumption.
- When retrofitting, replacing equipment with more efficient models often offers the greatest potential for savings.
2. Controllability and flexibility
- New fans are infinitely variable, enabling volume flow to be adjusted as required (e.g. CO₂ or humidity-controlled regulation).
- This makes systems not only more efficient, but also more convenient to operate.
3. Space and installation conditions
- Retrofit solutions usually take into account that the existing system will continue to be used.
- Therefore, there are plug-and-play fans that can be installed in existing housings.
- More compact designs are also available, which is particularly advantageous in confined technical centres.
4. Plant performance
- The replacement allows volume flows and pressure ratios to be better maintained or adjusted.
- This means that heat recovery systems or higher-class filters can also be operated retrospectively without overloading the fan.
5. Noise generation
- New fan models are usually quieter thanks to optimised impellers and airflow.
- This is particularly relevant for retrofits in office buildings, schools or hospitals.
6. Operating costs and maintenance
- Lower power consumption reduces running costs.
- Modern EC fans require less maintenance than older belt or asynchronous motor solutions.
- Monitoring and diagnostic tools (e.g. via bus system) can be integrated.
| Kriterium | Altventilator (Bestand) | Retrofit-Ventilator (neu, z.B. EC) |
|---|---|---|
| Wirkungsgrad | 40- 60% | 70 – 85% |
| Motor | Asynchronmotor, meist mit Riemenantrieb | EC-Motor (direkt an Laufrad), sehr effizient |
| Regelbarkeit | Nur Stufenschaltung oder Drosselung | Stufenlos, integrierte Drehzahlregelung |
| Energieverbrauch | Hoch, da oft auf Volllast ausgelegt | Bis zu 30–50 % Einsparung möglich |
| Geräuschentwicklung | Höher (Riemen, ungünstige Strömung) | Deutlich leiser durch optimierte Laufräder |
| Platzbedarf | Größer, zusätzliche Antriebskomponenten | Kompakter, direkt im Luftstrom |
| Wartung | Riemenwechsel, Lagerpflege, mehr Aufwand | Gering, da riemenlos und mit langlebigen Lagern und digitale Überwachung möglich |
| Steuerung / Monitoring | Analog, kaum Diagnosemöglichkeiten | Digital einbindbar (Bus-Systeme, Fernüberwachung) |
| Lebensdauer | Eher kürzer, hoher Verschleiß | Längere Lebensdauer, stabile Performance |
| Nachrüstung von Funktionen | Begrenzte Anpassbarkeit | Ermöglicht Einbau effizienterer Filter oder Wärmerückgewinnung durch höheren Druckaufbau |