Bring legacy systems into the future, one step at a time!
Retrofit Automation with Confidence
Ageing plants, mines, and manufacturing facilities often operate with little to no real-time monitoring or fault detection, yet full-scale automation can feel expensive, risky, or out of reach. That’s where NewElec steps in.
The Why Wait to Automate™ initiative helps you gain operational visibility via HMI/PLC and improved uptime by retrofitting intelligent motor protection relays, without replacing your MCCs or rewiring your plant.
Whether you’re running legacy control panels or outdated protection devices, NewElec’s retrofit-ready relays help you improve performance, reduce risk, and lay the groundwork for future upgrades.
Modernise Without Overhauling – The Benefits of NewElec’s Retrofit Solutions
- Extend Equipment Life by 20–30 Years – Detects faults early and reduces motor strain with real-time monitoring and protective relays.
- Enable Smarter Maintenance Decisions – Track performance trends and respond before breakdowns occur, reducing downtime and unplanned repairs.
- Improve Energy Efficiency – Monitor kVA and kVAR metrics to optimise load usage and cut unnecessary energy waste.
- Support Safety and Compliance – Earth Leakage and Fault Detection relays help protect operators and meet industrial regulations.
- Plant Status Checks – Check the status of all starters on MCC from a safe location within the substation.
- No Full Automation Required – Plug-and-play setup fits into existing MCCs without complex rewiring or self PLC programming.
Why Visibility & Early Fault Detection Matter
- Unplanned Downtime Costs: Unplanned downtime can cost manufacturers up to R4,731,948.00 per hour, with outages averaging four hours and totaling approximately R36,399,600.00 per event. (source: iiot-world)
- Predictive Maintenance Benefits: Implementing predictive maintenance strategies can lead to a 52.7% reduction in unplanned downtime and a 78.5% decrease in defects. (source: coastapp)
- Equipment Failure Statistics: Equipment failure accounts for 80% of all unplanned downtime in manufacturing settings (source: twi-institute)
Fact: A study by McKinsey & Company indicates that South African mining companies experience nearly 40% more unplanned maintenance compared to global peers, primarily due to insufficient equipment monitoring. Implementing advanced analytics and predictive maintenance strategies could reduce maintenance costs by up to 20% and increase throughput by 6%.
NewElec’s solutions are designed specifically to unlock this kind of value, without the need for full automation or infrastructure replacement.
Which Relays Power This Transformation?
NewCode Relay – Smart protection for low-voltage to medium-voltage motors with integrated diagnostics and short-circuit, earth fault, thermal overload, and breaker failure protection. Learn More About NewCode Relay.
MA Series Relay – Reliable motor protection with thermal overload, PTC inputs, short-circuit, and unbalanced current protection, ideal for water treatment and industrial process applications. Learn More About MA Series Relay
Who Is This For?
- Mine’s operating with legacy MCCs
- Ageing industrial facilities, plants, and quarries seeking uptime gains
- Water plants, material handling, and aggregate operations
- Engineering teams focused on measurable improvements, not full digital overhauls
Results That Matter
- Existing plant control with optional automated control, which can now be linked to Local control HMI or centralised control SCADA
- Improved personnel safety
- No need to open MCC cubicle during fault finding
- Comprehensive protection, earth leakage, as well as a frozen contactor
- IRDA through door communication, NewCode configuration
- NewCode memory module retains relay configuration settings
- Standard HMI/PLC module extracts customiaed shift reports
- Direct link to engineering /foreman/production supervisor/desktop
- Maintenance staff are directly involved in commissioning and are able to take ownership and continue with production optimisation
Client Feedback Speak Volumes
“The support team based in South Africa was outstanding! They remotely guided me through a tricky relay programming issue step-by-step. Their expertise turned a major roadblock into a smooth resolution. It’s reassuring to know there’s a team like this behind the products we rely on.” — Electrical Foreman, Copper Mine, Africa
Trusted for Over 45 Years
NewElec is South Africa’s leading motor protection and automation partner. With advanced features, long product lifespans, and industry-leading support, we help you maximise asset performance without major capital investment.
Contact NewElec For a Consultation Today
