Introduction
Legacy CNC control systems in packaging machinery don't just age—they fail, lose support, and leave operators scrambling for obsolete parts while production lines sit idle. The average packaging line operates for 12–15 years, well beyond the typical support window for most control electronics. When a 10-year-old form-fill-seal machine's motion controller dies, the choice is stark: replace the entire machine for six figures, or swap the control board for a fraction of that cost and extend the asset's life by another decade.
CNC retrofit boards restore precision motion control to packaging equipment—cartoners, case packers, labelers, and vertical baggers—without the capital outlay of full replacement. In packaging applications, these boards must handle a specific set of demands:
- Handle multi-axis electronic gearing across coordinated motion sequences
- Execute cam profiles for rotary cutting or sealing operations
- Interface with servo or stepper drives across multiple machine generations
- Deliver encoder-based registration correction to keep seal bars synchronized
Choosing the right board manufacturer determines whether your retrofit delivers years of uptime or months of troubleshooting.
TLDR
- CNC retrofit boards replace outdated control electronics, restoring precision and adding modern features for 60–70% of new machine cost
- Choose based on axis count, servo/stepper compatibility, software support (LinuxCNC or proprietary), and cam profiling for packaging
- Options span open-source specialists like Mesa and Pico Systems up to industrial platforms from Siemens and Beckhoff
- Budget, existing servo hardware compatibility, and technical support availability drive most integrator decisions
Overview of CNC Retrofit Boards in the Packaging Machinery Industry
A CNC retrofit board is a hardware interface card or motion controller PCB that replaces the original control electronics in packaging equipment. It connects legacy or modern servo/stepper drives to a new software control layer, handling the real-time motion commands that position film, activate seal jaws, synchronize cutting knives, and correct registration errors.
Unlike a full retrofit kit (which includes drives, motors, cables, and software), the board is the core motion control brain. It's the right choice when existing mechanical systems and motors are still serviceable.
Packaging machinery represents a massive retrofit opportunity. The global packaging machinery retrofitting market reached USD 9.45 billion in 2025, projected to hit USD 13.34 billion by 2030. Retrofitting delivers 70–80% of a new machine's performance for only 60–70% of the capital cost, extending asset life by 8–12 years. For fill-seal and cartoning machines—which account for over half of retrofit projects—board-level upgrades offer faster ROI than full line replacement.
Those performance gains depend on choosing a board built for packaging-specific demands. Packaging applications require capabilities absent from general-purpose CNC controllers:
- Multi-axis electronic gearing to synchronize film drive with product flow
- Encoder-based registration correction to adjust for print-mark drift
- Safe-torque-off compliance (IEC 62061, ISO 13849 PLe) for food and pharma lines
- Deterministic real-time communication (EtherCAT, SERCOS III, or step/direction) to coordinate high-speed axes with sub-millisecond precision
These demands separate packaging-capable boards from general-purpose CNC controllers.
Top 10 CNC Retrofit Board Manufacturers for Packaging Machinery
The following manufacturers were evaluated on motion control capability, packaging-industry relevance, software ecosystem maturity, axis scalability, and field-proven reliability. Order does not imply ranking.
Pico Systems
Pico Systems, based in Kirkwood, Missouri, specializes in motion control interface boards and components that bridge different control architectures. The product line covers servo amplifier interfacing, position tracking through emergency-stop events, and deep LinuxCNC compatibility—making it a practical fit for integrators building custom automation or retrofitting legacy packaging lines on open-source control software.
Where Pico Systems stands out:
- Interfaces between dissimilar control hardware layers (e.g., LinuxCNC to analog servo drives, PWM amplifiers to encoder feedback systems)
- Position-retention during E-stop events—critical for registration-sensitive packaging lines where losing position reference means scrapping in-process products and time-consuming re-registration
- Encoder converters for Fanuc and Panasonic motors extend reuse of existing hardware on custom builds
| Category | Details |
|---|---|
| Key Products | Universal Stepper Controller (4-axis, 250 kHz step rate), Universal PWM Controller (4-axis, 10 MHz encoder counting), 4-axis DAC16 (16-bit analog ±10V), Gecko Interface, Copley Interface |
| Software Compatibility | LinuxCNC (via PPMC driver), machinekit distribution for BeagleBone-based CRAMPS board |
| Best Fit For | Custom packaging machine builds, LinuxCNC-based retrofits, servo amplifier interfacing projects, cost-sensitive retrofits reusing existing drives |
Mesa Electronics
Mesa Electronics manufactures FPGA-based motion control and I/O cards with a strong track record in LinuxCNC retrofit projects. Their catalog includes PCI, PCIe, and Ethernet-connected cards handling step/direction, encoder feedback, and analog servo interfaces.
What integrators rely on:
- Deterministic Ethernet communication via HostMot2 firmware with flexible I/O expansion
- Active open-source community with deep documentation and user forums
- Proven field record on packaging line retrofits running LinuxCNC
| Category | Details |
|---|---|
| Key Products | 7i76E Ethernet motion control card (5-axis step/direction, 48 isolated I/O), 7i92 Ethernet I/O card (parallel port replacement) |
| Axis Support | Up to 5 coordinated axes per card; expandable via additional cards on same Ethernet network |
| Best Fit For | LinuxCNC-based packaging retrofits, integrators comfortable with open-source ecosystems, budget-conscious projects reusing existing stepper/servo drives |
Galil Motion Control
Galil, a California-based motion controller manufacturer, offers standalone and embedded controller form factors with a long track record in multi-axis servo and stepper control for industrial automation and packaging equipment. Their DMC series controllers deliver deterministic command execution and built-in synchronization functions.
Built-in synchronization for packaging motion:
- Built-in electronic gearing and camming functions for synchronizing rotary knives, labelers, or pick-and-place systems
- High-speed registration input support with position latch capture within 25 µs
- Deterministic DMC command language (GCode-like) simplifies multi-axis coordination in web-tension or form-fill-seal applications
| Category | Details |
|---|---|
| Key Products | DMC-40x0 series (1–8 axes), supporting electronic gearing, electronic cam, high-speed position latch |
| Communication Interface | Dual Ethernet ports, RS-232, optional EtherCAT support |
| Best Fit For | Multi-axis synchronization, electronic cam applications in form-fill-seal, labeling, or cartoning machinery |
Beckhoff Automation
Beckhoff, a German automation manufacturer, developed PC-based control and the EtherCAT fieldbus protocol. Their TwinCAT software paired with EtherCAT-capable I/O and motion terminals can replace legacy PLC+motion boards in packaging lines, with cycle times as low as 62.5 µs for deterministic synchronization across high axis counts.
Packaging industry adoption:
- Native support for electronic gearing, cam tables, and Safety-over-EtherCAT (FSoE)
- Used by major packaging OEMs including Bausch+Ströbel (labeling), SEALPAC (packaging), and Weightpack (filling)
- ELM72xx servo terminals drive motors up to 16 A directly from the I/O rack
| Category | Details |
|---|---|
| Key Products | EL7xxx EtherCAT servo terminals, CX-series embedded PCs, TwinCAT 3 software platform |
| Software Ecosystem | TwinCAT 3 (IEC 61131-3 + C/C++), EtherCAT master with cycle times as low as 62.5 µs |
| Best Fit For | High-axis-count packaging lines, safety-rated retrofits, facilities standardized on EtherCAT infrastructure |
Centroid CNC
Centroid, a U.S. manufacturer, specializes in PC-based CNC retrofit control systems for modernizing Bridgeport-style mills and industrial machinery. Their retrofit kits include the control board, drives, and configuration software, with an emphasis on ease of commissioning and reuse of existing servo motors.
Turnkey retrofit advantages:
- Self-contained board-plus-software solution simplifies integration for packaging OEM rebuilders
- CNC12 software includes conversational programming, reducing operator training requirements
- Pre-wired electrical cabinet options (M-39) reduce installation time on the floor
| Category | Details |
|---|---|
| Key Products | Acorn (4-axis, 400 kHz step/direction), M-39 (up to 8-axis AC/DC servo support) |
| Servo Compatibility | AC/DC servo motors, step/direction stepper drives; pre-configured for common drive brands |
| Best Fit For | Packaging OEM rebuilders seeking turnkey board+software retrofit with domestic U.S. support |
Delta Motion (formerly Delta Tau)
Delta Motion's PMAC (Programmable Multi-Axis Controller) platform, now part of Omron, targets demanding packaging applications requiring sub-millisecond servo loop closure and complex coordinated motion. The platform handles high axis counts and advanced kinematic algorithms.
Motion performance specs:
- Multi-axis synchronization with servo loop updates as fast as 31.25 µs
- Embedded camming and gearing for complex kinematic models
- Programming environment supports robotics-integrated packaging lines
| Category | Details |
|---|---|
| Key Products | Power PMAC, PMAC2 (up to 8 axes simultaneously with DSP-based calculations) |
| Axis Count | 8+ coordinated axes; scalable for complex multi-axis applications |
| Best Fit For | High-speed, high-precision packaging lines with robotic integration or complex coordinated motion |
Bosch Rexroth
Bosch Rexroth's IndraMotion MTX and IndraControl retrofit platforms modernize existing packaging machinery with a consistent hardware/software architecture across servo drives and control boards. The platform is designed for scalability and modular machine concepts.
Scale and integration strengths:
- Presence in OEM lines for cartoning, palletizing, and filling equipment
- Scalable up to 64 axes and 12 independent CNC channels
- IndraControl L series offers DIN-rail mounted CNC solution for space-constrained retrofits
| Category | Details |
|---|---|
| Key Products | IndraMotion MTX, IndraControl L series (modular CNC + PLC) |
| Communication Standards | SERCOS III, PROFIBUS, EtherNet/IP for seamless plant network integration |
| Best Fit For | Facilities standardized on Rexroth drives; medium-to-large packaging line modernization projects |
Parker Hannifin (Automation & Motion Division)
Parker Hannifin's automation division supplies servo drives, motion controllers, and retrofit board solutions under the Compumotor and Aries product lines for packaging and material handling applications. Single-vendor sourcing across the motion system simplifies support and procurement.
Single-vendor sourcing benefits:
- Single-vendor BOM for retrofit boards, servo drives, and linear actuators simplifies support escalation
- 1 µs position capture capability for high-speed registration correction
- Aries Controller combines drive and controller in one compact unit for single-axis upgrades
| Category | Details |
|---|---|
| Key Products | ACR9000 motion controller (up to 16 axes via Ethernet Powerlink), Aries Controller (integrated drive+controller) |
| I/O & Fieldbus | EtherNet/IP, CANopen, USB 2.0; supports mixed stepper and servo technologies |
| Best Fit For | Integrators wanting single-vendor motion + drive + mechanical components for packaging retrofit |
Omron Automation
Omron's Sysmac platform converges PLC, motion, vision, and safety control on a single architecture used in packaging OEM builds. The platform has particular depth in food and beverage applications where integrated safety certification matters.
Safety and motion integration:
- Deep presence in food and beverage packaging lines
- NX-SL safety CPUs certified for IEC 61131-3, IEC 62061, and ISO 13849 PL e, integrating safety directly into the EtherCAT network
- PLCopen motion control blocks for single-axis positioning, electronic cams, and multi-axis coordination
| Category | Details |
|---|---|
| Key Products | NX102 Machine Automation Controller (up to 8 axes, 256 EtherCAT nodes), NX-SL safety CPUs |
| Safety Integration | Integrated functional safety (IEC 62061 / ISO 13849 PLe) via CIP Safety over EtherCAT |
| Best Fit For | Food and beverage packaging lines, facilities already using Omron PLCs and vision systems |
Siemens (SINUMERIK / SIMATIC Motion)
Siemens holds the largest installed base among CNC control manufacturers globally. Their SINUMERIK ONE and SIMATIC S120 drive-control boards are used to retrofit large-format packaging and converting machinery where the Siemens ecosystem is already entrenched.
Retrofit program specifics:
- Dedicated Retrofit with SINUMERIK ONE services to upgrade older CNCs
- Digital native CNC supporting 31.25 µs current control cycles and integrated SIMATIC S7-1500F PLC
- Higher cost and vendor lock-in are trade-offs for an unmatched global support network
| Category | Details |
|---|---|
| Key Products | SINUMERIK ONE CNC, SINAMICS S120 modular drive system (Booksize and Chassis formats) |
| Scalability | Scalable multi-axis configurations; SINAMICS S120 supports modular expansion for complex applications |
| Best Fit For | Large converting, printing, or complex multi-axis packaging lines with existing Siemens infrastructure |
How We Chose the Best CNC Retrofit Board Manufacturers
Manufacturers were assessed on four criteria: motion control capability (axis count, update rates, feedback types), packaging-industry applicability (cam/gearing support, registration inputs, safety ratings), software ecosystem maturity, and access to technical support or active user communities.
One common mistake: selecting a manufacturer on brand name alone without confirming servo drive compatibility with existing hardware. That mismatch can derail an entire retrofit project before it starts.
Packaging-specific technical criteria that separated strong candidates:
- Real-time communication via EtherCAT, PROFINET IRT, or SERCOS III with cycle times under 1 ms
- Electronic gearing and cam table support for synchronizing rotary knives, labelers, or seal jaws
- Encoder-based registration correction with position latch functions under 25 µs for print-mark tracking
- SIL 2 / PLe functional safety compliance, increasingly required in food and pharma lines
Not every retrofit demands enterprise-grade fieldbus standards. For integrators working with legacy hardware, open-source-compatible boards from Pico Systems and Mesa Electronics provide a cost-effective alternative — LinuxCNC-compatible solutions that let you reuse existing drives and motors while adding modern control capabilities, without proprietary lock-in.
Conclusion
The right CNC retrofit board manufacturer for packaging machinery depends on three converging factors: the existing servo/drive hardware on the line, the motion complexity of the application (simple point-to-point vs. high-speed electronic camming), and the long-term support and software ecosystem the integrator or end-user can sustain.
Beckhoff, Siemens, and Omron sit at the high end — integrated safety and tight synchronization performance, but with ecosystems that require real commitment. Galil, Bosch Rexroth, and Parker offer proven industrial reliability with broader drive compatibility at mid-range budgets. For cost-sensitive projects, Mesa Electronics and Pico Systems give integrators the most hardware flexibility without locking into a proprietary stack.
Request a hardware compatibility checklist from any shortlisted manufacturer before committing. At minimum, verify:
- Encoder feedback type — single-ended vs. differential, and voltage levels
- Drive interface protocol — analog ±10V, step/direction, or fieldbus
- Real-time OS requirements — especially relevant for LinuxCNC-based builds
- Safety certification level — matched to your packaging machine's requirements
For integrators working with LinuxCNC-based packaging retrofits or needing specialized servo amplifier interfaces, Pico Systems offers PWM servo interface boards, analog servo interfaces (PPMC), and stepper controllers designed for precisely these retrofit scenarios. Contact Pico Systems at elson@pico-systems.com or +1 314-965-5523 to discuss compatibility with your existing hardware.
Frequently Asked Questions
What is a CNC retrofit board for packaging machinery?
A CNC retrofit board is a motion control hardware card that replaces obsolete control electronics in existing packaging equipment, connecting servo or stepper drives to a modern software control layer without requiring a full machine replacement.
How is a CNC retrofit board different from a full CNC retrofit kit?
A retrofit board is the core motion control PCB only, while a full kit includes drives, motors, cables, and software. Integrators often source the board separately when reusing existing servo motors and drives to reduce cost.
What axes of motion do packaging machinery retrofit boards typically support?
Most industrial-grade retrofit boards support 4–8 coordinated axes as standard, with high-end platforms scaling beyond 32 axes. Packaging applications typically require at least 4–6 axes for film drive, cross-seal, fill, and registration correction.
Can CNC retrofit boards for packaging work with LinuxCNC?
Yes—boards from Mesa Electronics and Pico Systems are specifically designed or compatible with LinuxCNC, making them a practical choice for packaging retrofit projects where teams prefer open-source control software for flexibility and lower licensing overhead.
What certifications matter most when selecting a retrofit board for a packaging line?
CE marking, UL/cUL listing, and functional safety certifications (IEC 62061, ISO 13849 PLe/SIL 2) are most critical for packaging environments, especially food, pharma, and beverage lines subject to regulatory audits.
How much does a CNC retrofit board for packaging machinery typically cost?
Pricing varies widely by platform:
- Under $500: Entry-level, open-source-compatible boards (Mesa Electronics, Pico Systems)
- $1,000–$5,000: Mid-range industrial controllers (Galil, Centroid)
- $5,000+: High-end systems (Siemens, Beckhoff)
Board cost is a fraction of total project spend once labor, drives, and integration are factored in.
