Modernize Your Splicers. Maximize Your ROI.

Upgrade your trusted Butler Automatic splicers with modern controls, enhanced safety features, and smart automation—at a fraction of the cost of new capital equipment.

 
 

 Why Replace When You Can Modernize?

Butler Automatic splicing machines are built to last for decades, but electrical components, PLCs, and drive systems naturally face obsolescence over time. A factory-certified retrofit restores peak performance, resolves component availability issues, and integrates modern digital capabilities into your existing mechanical footprint.

Core Retrofit Package Upgrades

What's Included in a Butler Splicer Upgrade?

  • Controls & PLC Modernization Replace end-of-life PLCs and obsolete relays with current-generation industrial controllers, ensuring easy troubleshooting and long-term spare parts availability.

  • Modern Touchscreen HMIs Intuitive multi-language interfaces feature clear diagnostics, simple recipe management, and real-time operational feedback for faster operator onboarding.

  • Drive & Servo Systems Upgrade to modern, energy-efficient servo motors and drives for precise tension control, improved splice reliability, and reduced scrap rates.

  • Enhanced Safety Integrations Bring older machinery into full compliance with updated global safety standards (ANSI/OSHA/CE) through modernized e-stops, safety relays, and light curtains.

  • IIoT & Remote Connectivity Enable remote diagnostics, automated production reporting, and seamless integration into your facility’s SCADA or MES systems.

The Retrofit Process

1. On-Site or Virtual Audit:Evaluating machine condition.

Our field engineers inspect your existing equipment, evaluate component degradation, and establish clear modernization goals for your specific production line.

2. Custom Package Design:Tailored engineering solutions.

We engineer a drop-in electrical and control retrofit tailored to your production speeds, web materials, and control systems.

3. Factory Testing & Pre-Assembly:Minimizing plant downtime.

All control panels and wiring harnesses are assembled and pre-tested at Butler Automatic to ensure rapid field deployment.

4. On-Site Installation & commissioning:Seamless turn-key startup.

OEM-certified technicians execute the retrofit, calibrate tension controls, run trial splices, and train your plant operators and maintenance technicians.

Ready to Extend the Life of Your Equipment?

Contact our service team today with your serial numbers to discuss compatible upgrade paths and schedule an evaluation.

Download our retrofit whitepaper