What to Know Before Starting a Warehouse Retrofit Journey
Guest blog by Panos Gamvroudis, Product Manager Controls and Automation, Conductix-Wampfler (MHI member company)
Retrofitting a warehouse is becoming a necessary step for facilities trying to keep up with automation needs. It’s an opportunity to refresh systems, equipment, or operational processes that may be outdated or simply not producing consistent results – without starting from scratch.
Small, intentional changes to pre-existing warehouse space are more cost-effective and less time-consuming than a completely new build, and many teams are prioritizing retrofits as a faster path to modernization.
In the age of smart warehousing, many retrofit journeys are sparked by the need for added infrastructure, technology, or automation to handle increasing throughput and system complexity. According to a Control Engineering piece, 80% of U.S. warehouses were built before automation emerged as a key tool for improving productivity and efficiency.
That means the industry is ripe for retrofitting, but it’s also facing a challenge: modern systems are being layered onto infrastructure that wasn’t designed to support them. A successful retrofit project isn’t possible without strong power and data infrastructure. It is the foundation for unlocking the benefits of automation while supporting current demand and preparing for the future.
In this piece, we’ll explore how to approach a successful retrofit journey – from understanding your pain points to investing in scalable power and data infrastructure and preparing for what’s next.
Identify Opportunities for Improvement
To help navigate ongoing macroeconomic challenges, many facility managers are turning to warehouse redesigns to update layouts, upgrade infrastructure, and integrate automation. Before investing in retrofits, start by identifying where performance is breaking down. In many cases, the root cause sits in the foundation – power and data infrastructure.
Retrofitting a warehouse is not a one-size-fits-all exercise. It requires a tailored approach to effectively respond to specific issues. Consider the following:
• Are you experiencing Wi-Fi dropouts or inconsistent connectivity?
• Is latency increasing under peak periods?
• Are operators feeling fatigued or overwhelmed with demand?
Many of these challenges can be traced back to fragmented power and data communication between equipment and systems. These issues don’t just affect productivity, but they create bottlenecks that limit how much automation can actually deliver. By clearly understanding these challenges, you can prioritize retrofits that address root causes and support future operations.
Invest in the Right Infrastructure
Automation is a key driver of investment across the manufacturing industry. And that focus is only expected to grow. In fact, the warehouse automation market is projected to reach $59.52 billion by 2030. Because of this, facility managers are retrofitting existing systems to support increased demand and improve productivity. But automation performance ultimately depends on the infrastructure supporting it. If power delivery or data communication is inconsistent, even advanced automation systems will struggle to perform reliably.
Modern automated systems require increased electrical capacity, reliable connectivity, and strong data communication. Facilities built over 20 years ago are not equipped to handle automation without significant upgrades to charging and data architecture.
To address latency and dropout issues, consider data-over-power, or Powerline Communication (PLC), technology. Instead of relying on wireless networks that can introduce interference and coverage gaps, PLC transmits data directly through existing power infrastructure and removes a common point of failure.
These solutions are designed to work across various conductor profiles, including conductor rails, cable reels, festoons, cable chains, and slip rings. They can be used on existing systems to add a secure data communication layer or replace Wi-Fi when issues arise, often without requiring major structural changes or downtime.
Establishing a strong data foundation enables more reliable automation throughout your retrofit journey. Tracking real-time performance helps identify bottlenecks, improve worker safety, and support better decision-making over time.
Additionally, ensuring that charging infrastructure can support increased automation demand is key. AGV and AMR solutions depend on consistent charging to maintain throughput. Consider integrating hybrid charging deployments that combine conductive and inductive charging solutions. These deployments offer both fast-charging docks for scheduled stops and wireless pads for opportunistic charging as vehicles pass through work zones.
This approach reduces downtime while giving operations more flexibility as demand increases.
Prepare for Tomorrow, Today
One of the main benefits of a retrofit journey is the ability to take a phased approach. By prioritizing updates that improve efficiency and scalability, facilities can modernize without jeopardizing throughput or spreading resources too thin. But success hinges on whether the underlying infrastructure can support both current demand and future growth.
As you begin a retrofit journey, evaluate whether your existing infrastructure can handle the increasing demands of automation, connectivity, and real-time data communication. Investing in flexible, modular systems supports upgrades today without limiting what’s possible tomorrow. This approach not only generates immediate performance improvements but also enables facilities to adapt as the industry and operational needs evolve.
Another important consideration is working with experienced partners who understand how to align infrastructure, automation, and long-term strategy. The most successful retrofits are those where infrastructure is designed to support long-term performance and not just immediate upgrades.
When power and data are treated as the foundation, facilities are better positioned to scale efficiently, improve reliability, and remain competitive in an increasingly automated landscape.
