Author: HWS Mainz Laboratory Engineering Team
Published by HWS Mainz – Specialists in Custom Glass Reactor Systems for Laboratories and Industry, offering insights on the latest glass reactor upgrades.

Introduction: When Your Reactor Needs an Upgrade

In every research or production lab, even if you do an amazing maintenance, there comes a time when your glass reactor setup no longer fits your needs. Maybe your workflow has changed. Maybe you need to integrate sensors or new automation tools. Or perhaps you’ve started working with more aggressive media, and your existing system can’t keep up.

At this point, you’re faced with a common question: Should you retrofit your existing reactor—or invest in a brand-new one?

At HWS Mainz, we work closely with chemical engineers, lab managers, and R&D professionals to help them answer that question. In this article, we’ll walk through the decision-making process, the pros and cons of each option, and how our team supports both retrofits and fully custom new builds.

Retrofitting: When to Upgrade What You Already Own

Retrofitting refers to modifying an existing glass reactor to meet new functional requirements. This might involve:

• Adding extra ports or inlets/outlets
• Replacing damaged or outdated glass components
• Integrating temperature or pressure sensors
• Swapping in a new bottom valve or stirrer guide
• Upgrading clamps, joints, or flanges for compatibility with other systems

When Retrofitting Makes Sense

Retrofitting is often the best option if:

• The core vessel is intact and high-quality
• Your needs involve modest changes, such as adding ports or adjusting outlet configuration
• You want to minimize downtime and avoid lengthy approvals for equipment replacement
• Budget constraints require a cost-effective solution

At HWS, we frequently retrofit:

• Older Schott or HWS reactor bodies that still meet structural requirements
• Single-wall vessels that need new jackets or thermal integration
• Bottom valves that need replacement due to wear or chemical incompatibility

Because all our parts are modular and traceable by serial number, we can match components precisely—even years after original delivery.

Benefits of Retrofitting

• Lower cost vs buying new
• Faster turnaround time (especially for minor changes)
• Less waste, more sustainable
• Maintains lab familiarity and compatibility

When to Consider a New Reactor System

Retrofitting has its limits. Some upgrades simply can’t be accomplished without compromising safety, performance, or long-term reliability. In those cases, a new reactor build is the smarter investment.

Signs You Need a New System

• The vessel has structural damage or surface degradation (scratches, fogging, microfractures)
• Your new process requires larger volume, pressure rating, or thermal integration than the vessel allows
• You’re implementing automated systems that require complete redesign of connections and ports
• You want to future-proof your setup for upcoming workflows or expansions

Advantages of Building New

• Full flexibility in layout, volume, materials, and port configuration
• Ability to integrate modern standards (inert gas lines, automation ports, drain valves, etc.)
• Certainty that all components meet current lab safety and quality requirements
• Option to test new setups before full process scale-up

At HWS, our custom new builds are crafted from Type I, Class A borosilicate glass and feature fully configurable:

• Flange systems and port geometries
• Jacketed or triple-walled designs
• Magnetic or pneumatic outlet valves
• Stirrer guides, condensers, and sensor ports

Our engineers collaborate directly with your team or external designers to ensure your new reactor fits seamlessly into your lab’s process ecosystem.

Retrofitting vs Buying New: Side-by-Side Comparison

Feature/Need	Retrofit Existing Reactor	Custom New Reactor
Cost	Lower	Higher initial investment
Turnaround Time	Shorter (1–4 weeks typical)	Longer (4–8 weeks typical)
Customization Scope	Limited	Extensive
Risk of Compatibility Issues	Moderate	None
Equipment Lifetime	Depends on base vessel	Fully renewed
Sustainability	Reuse existing components	New build (recyclable)

How HWS Supports Both Pathways

HWS is uniquely positioned to support both retrofit and new reactor builds. Our in-house glassblowing shop and CAD engineering allow us to:

• Recreate broken or worn glass parts based on serial number or sample
• Add custom ports or flanges to existing vessels
• Adapt old systems to fit new stirrers, temperature controllers, or sensors
• Design entirely new systems tailored to your reaction, scale, and layout

Whether you’re working with legacy HWS equipment, Schott glassware, or another manufacturer’s components, we’ll assess your setup and recommend the best course forward.

We also maintain documentation for nearly all past projects—so if you need to rebuild or upgrade a 10-year-old reactor, we likely have the original specs.

Frequently Asked Questions

Can I retrofit a jacket into an existing single-wall reactor?

Sometimes. It depends on the vessel shape and wall thickness. Our team can assess viability and offer alternatives such as external heating mantles or custom triple-wall builds.

Can you add a PT100 sensor port to an older HWS reactor?

Yes. We can drill and fuse new sensor ports into existing heads, bottoms, or sidewalls if structural integrity allows.

Is retrofitting safe?

Absolutely—when done professionally. We follow the same safety and quality standards for retrofits as for new builds, including stress tests and final inspections.

Do I need to ship my reactor to HWS for retrofit work?

Not always. We can replicate parts from drawings, photos, or existing serial numbers and ship compatible components for on-site installation.

Conclusion: Choose the Right Path for Your Lab

The decision to retrofit or build new depends on your goals, constraints, and the condition of your current reactor. But whichever path you choose, HWS offers a trusted, proven way forward.

With decades of experience in scientific glassware, a modular system architecture, and unmatched customization capability, we help labs evolve their glass reactor systems with confidence.

Let’s make your glassware work better—for your chemistry, your budget, and your future.

Need help deciding?

Here is a Labmanagar article that offers a broader view of lab upgrade decisions beyond reactors.

Contact our technical team to evaluate your reactor and get tailored recommendations: info@hws-mainz.de