Automation for optimised production processes

This project involved the virtualisation of the automation and IT infrastructure of Solupharm Pharmazeutische Erzeugnisse GmbH. The main task was to modernise an existing production line by converting physical IT resources into virtual machines to ensure greater flexibility, reliability and lower costs.

HEITEC developed a fully automatic laser setting system for fountain pen nibs for the German market leader for writing instruments. In order to meet the high quality standards, it is necessary for each nib tip of a writing tip to be straightened. The two nib legs are to be straightened to a predefined gap dimension.

Planning, engineering and production of navigation and communication systems, as well as low-voltage switchgear. Planning of the entire cable system.

Increasing the safety and quality of the media supply for aseptic filling of syringes, cartridges and vials.

Planning, engineering and production of navigation and communication systems, as well as low-voltage switchgear.

Carl Schlenk AG is a leading international manufacturer of metal powders, effect pigments and metal foils. With a new building, Schlenk also wanted to reorganise its logistics processes in production with the aim of gaining an overview of material consumption and material receipts in real time.

It was becoming increasingly difficult to procure spare parts for an order picking warehouse from the 1990s, including the control technology based on Simatic S5, as the control components had been discontinued for some time. The risk of long, incalculable downtimes in the event of a component failure grew steadily. Continuous safe operation was no longer guaranteed. HEITEC was commissioned to analyse the current situation and the risk of failure and to carry out the retrofit.

Hengstenberg GmbH & Co. KG develops and produces sour, wine vinegar and delicatessen products and stores its products in a high-bay warehouse at its site in Bad Friedrichshall. Three storage and retrieval machines supply two storage areas, which can accommodate single or double pallets. The companies Artschwager & Kohl Software GmbH and HEITEC AG were commissioned to modernise the three storage and retrieval machines, the conveyor technology and the safety equipment in the final packaging, storage and canning areas as well as the warehouse management system.

The AWT system at Fulda Hospital controls around 360 transport containers underground and away from the flow of patients, with the help of which the supply and disposal of each hospital ward is ensured. The modernisation was intended to ensure the availability of the AWT system in the future and find a solution for the problematic procurement of spare parts as well as enable future expansions of the system. In addition, the basic functionality of the system had to remain as unchanged as possible despite the implementation of modifications and troubleshooting in order to minimise the training requirements for the hospital staff.

The high-bay warehouse, built in 1980, has a capacity of 3,800 storage locations, which are divided into eight racks. Previously, the processes were controlled with SIMATIC S5 135U and operated via COROS. Many of the HW components were discontinued at the end of the 1990s and a continuous supply of spare parts was no longer guaranteed. In order to ensure the availability of the high-bay warehouse in the future, it was necessary to modernise the control and drive technology as well as the safety technology.

HEITEC AG was commissioned by Loparex Germany to modernise one of its existing film winders with the designation "Winder E27". A retrofit was necessary to ensure the operation of the system with increased availability, current safety standards and a guaranteed supply of spare parts for the future. This was based on the consideration that a retrofit can be more sensible for existing systems than replacing them with new ones, as it results in less downtime and lower costs. By replacing obsolete components and adding new, up-to-date technological developments, existing systems are brought back up to date. This reduces the risk of production downtime and employees can continue to work with the familiar technology, making extensive training unnecessary. A retrofit also has a positive effect on product quality.

A leading international company in the fields of variable camshaft phasing units and transmission valves commissioned HEITEC to virtually commission an existing plant in order to identify potentials with the help of the digital twin on the basis of a cycle time optimisation measure and thus initiate targeted retrofit measures. In addition, technologies from the field of special machinery and plant engineering such as bulk material separation with 3D image recognition, belt and film conveying, new drive and clamping processes as well as software-in-the-loop with Siemens PLCSIM Advanced and Epson robot systems posed new challenges.

Holopack Verpackungstechnik specialises in the contract filling of cosmetic and pharmaceutical products. Efficient filling technology plays a very important economic role here. Holopack was looking for a solution to increase production capacities in the manufacture of sterile and non-sterile, low to high viscosity pharmaceuticals. An intelligent automation solution with a batch management system was required to control the system - including a high-performance homogeniser.

Renner Etikettiertechnik is an internationally oriented supplier of professional labelling systems for the food and beverage industry. The automation specialist developed new technology components for the newly developed labelling system and integrated them into the overall system control. This was then tested on the digital model in order to recognise and rectify errors at an early stage.

Duscholux is one of the world's leading manufacturers of sanitary facilities. As a long-standing partner for the automation of production systems, HEITEC modernised the control technology. The aim was to further increase plant availability and production reliability.

VACUUMSCHMELZE (VAC) in Haunau develops, produces and markets speciality materials and products refined from them. The modernisation of the control and regulation technology was intended to increase the availability and operational reliability of five bell annealing furnaces. The systems were previously monitored and controlled via a centralised control system and a single operating and monitoring system. An important customer requirement was to be able to operate each furnace independently and to install an additional operating and monitoring system in the control room to manage and distribute recipes. In addition, the logging of process values was to be modernised and a convenient user administration system set up.

The Netzsch Group is a globally active family-owned mechanical engineering and equipment manufacturing company. The company built a new production facility in Selb for the manufacture and assembly of devices for thermal analysis, thereby expanding its capacity by 60 per cent. As the devices are increasingly geared towards customised requirements, Netzsch has streamlined its processes and geared them more efficiently towards individual production up to batch size 1, quality and efficiency. To achieve this, all processes had to be networked with each other.