Kraytek Automation

Extend the life of the equipment your operation runs on.

Kraytek Automation replaces aging control systems and, when it pays off, integrates the mechanical scope alongside. One team, one accountable scope — built for plant managers weighing a retrofit against a full replacement.

Talk to engineering See what we deliver

Featured in flexible packaging and web-based machinery. Delivered across every industrial vertical.

Certifications & partnerships

What we deliver

Control Systems Engineering

Most retrofits fail at the boundary between two vendors. Kraytek owns the mechanical scope and the controls scope together, so one team is accountable for the result.

Service 01

Control system retrofits

Complete replacement of obsolete PLCs, drives, HMI, and instrumentation on existing assets. Mature platforms stay in service another decade; spare parts and support stay available.

PLC / DCS migration
Drive & servo upgrades
HMI / SCADA redesign
Field instrumentation

Service 02

Mechanical integration

When the mechanical scope moves alongside the controls work, Kraytek owns it end-to-end. One procurement chain, one installation crew, one commissioning sign-off.

Converting & web handling
Servo & motion integration
Pneumatic / hydraulic upgrades
Safety guarding & access

Service 03

New line builds

Greenfield production lines engineered and assembled by Kraytek. From process definition through to operator training — built to run on day one and remain serviceable for the life of the line.

Process & layout design
Equipment specification
Integration & commissioning
Documentation & training

How we engage

One engagement, three deliberate steps.

From first walkdown to validated handover — one crew owns the project, one schedule dictates the work, one PO closes the loop.

Engagement process

Assess. Engineer. Deploy.

Step 01

Assess

Walkdown of the asset on-site: mechanical condition, controls stack, I/O count, fault history, and the operator’s day-to-day pain. Output: a one-page scope with the problems ranked, the boundary drawn, and an honest first cost.

Step 02

Engineer

Reverse-engineering, schematics, PLC/HMI code, and panel layout for both the mechanical rebuild and the controls re-platform. Bench-tested before shipping; documented as we go, so your team can service the result without us on the phone.

Step 03

Deploy

Installation, wiring, commissioning, and operator training on your floor, on your schedule. We stay through first-good production, hand over documentation, and remain on call for the warranty window.

Capability recovery

OEM out of business? We reverse-engineer it and put it back into service.

When the OEM disappears, your PLC parts go to six-week lead, your support ticket queue goes nowhere, and the operator-interface language drifts away from anything your maintenance crew can read. The line keeps running on borrowed time until it doesn't.

Rebuilt capability

Same machine, restored authority.

Kraytek reverse-engineers the original controls and mechanical scope side by side, re-platforms onto a current vendor stack, and ships the rebuilt machine under one crew, one schedule, one PO. You get today's spare-parts lead times and a documented asset that your own team can service without us on the phone.

Mechanical teardown + reverse-engineering
Controls re-platform onto a current vendor stack
Re-assembly + commissioning under one crew
Documentation + spare-parts plan for the next decade

Send the asset name, the controls stack, and the symptom. Engineering replies within one business day.

Talk to engineering

Customer voice

11 years, 20+ capability projects, one manufacturer.

A flexible packaging customer describes what the Kraytek engagement looked like over a decade.

11
Years of Partnership: 1/3
The cost of a new machine: 20+
Capability Projects Delivered

1/3 the cost of a new machine

delivered a 'new machine' on an old chassis

above-and-beyond after-sale support

— Flexible packaging manufacturer, Upstate NY

We are a flexible packaging manufacturer in upstate NY and started working with Kraytek about 11 years ago. Since then, they have helped us with dozens of projects from small to large scale implementations and improvements to our operation. Initially, we required a cross sealer and were looking at options. Kraytek understood bag machines and took the time to understand our needs. They had done this before so the design just needed to be tailored to our machine. We had talked to other machine builders about the project and Kraytek was a fraction of the cost of the others. Their time to implement was also considerably faster. Kraytek delivered a great solution and after implementation stayed connected to ensure it worked as intended.

Our next project was rebuilding a 1995 bag machine to current standards. Buying a new machine vs Kraytek's proposal to upgrade belt drives to servos, increase tension and web control and provide for easy operator interface was 1/3 the cost of a new machine. Kraytek's team delivered a 'new machine' on an old chassis that performs great. After the install, they have been there all the way to help with tweaks to ensure it runs as designed. The after sale support is above and beyond.

After the 2 projects mentioned above, we have implemented over 20 capability improvements projects across all our production lines. All of these projects gave us capabilities to drive new sales with new capabilities as well as reduce scrap and drive operational efficiency. Our operators are find them easy to operate and maintain. Kraytek is there for after sale support and questions. Since they use common components, we are buy replacement parts through national distributors. We still have new projects in the pipeline to implement and look forward to working with Kraytek to bring those to reality.

Industries served

Deep expertise in packaging. Capable in everything industrial.

Kraytek's roots are in converting and web-based machinery — but the engineering practice transfers cleanly to any industrial environment with aging controls.

Featured vertical

Flexible packaging & web-based machinery

Multi-axis web handling, tension control, and registration accuracy on the assets most plants are running 24/7. Deep expertise — not a line item.

Horizontal & vertical form-fill-seal
Pouch-making & bagger lines
Converting, coating & laminating
Labeling, slitting & rewinding

Food & beverage

General industrial

Converting & paper

Metals & materials

Pharma & medical

Consumer goods

The Kraytek difference

Built for the plant manager who has been burned before — by Kraytek Automation.

Three things separate a Kraytek retrofit from the usual scope of work: one team owns the whole result, the engineers have done it for decades, and modern tooling shortens the schedule without lowering the standard.

Accountability

Single point of accountability

Most retrofits drag because control vendors and mechanical vendors point at each other. Kraytek owns both scopes on the same project — one contract, one schedule, one name to call when something needs to move.

Mechanical + controls integrated under one team, one PO, one commissioning sign-off.

Experience

Decades of industrial expertise

A long history in packaging, converting, and process lines — the kind of know-how that only comes from hundreds of fielded retrofits. Engineers who have stood in front of a panel during a fault, not just designed one.

Engineers who have commissioned, not just specified. Vendor-agnostic — picked to fit the asset.

Delivery

AI-enhanced engineering

Modern tooling applied where it shortens schedule without cutting corners: code generation, fault-pattern review, and historical-troubleshooting recall. Used as an accelerator, never as a substitute for engineering judgment.

Faster delivery, deeper fault review, consistent documentation across every project.

Case study

A retrofit, measured against the alternative.

One full-line retrofit, packaging vertical. Compare the operational reality before and after the engagement — and the capex against the new-line alternative.

Before

Legacy line on borrowed time.

Twenty-something-year-old packaging line. The asset itself was sound; the controls stack had aged past the point of incremental repair.

PLC platform past end-of-life — spares on a six-week lead
HMI running on a Windows host that was last patched in 2017
Servo drives mismatched across stations — drift on changeover
No documentation reflecting the three PLC swaps of the last decade
Mechanical wear compounding the controls fault rate

After

Same asset, new control architecture.

Rails, drives, and HMIs replaced end-to-end — same mechanical footprint, same operator interface language, current vendor platforms underneath.

Uptime: +18%
Spares: 24h
Capex: ~40%
Compliance: current

Read the full case study on request — ask engineering at the contact form.

Start the conversation

Ready to engineer a better control system? Talk to Kraytek Automation.

Send a few sentences about the asset, the controls stack, and what triggered the conversation. Engineering reads every submission — no sales triage, no script.

Project inquiry

Five fields. Engineering responds within one business day.

Not ready to start a project?

Leave your email for future retrofit updates and a low-pressure conversation when the timing is right.

Have a question now? Send engineering a note directly.

Email engineeringkraytek-automation@polsia.app