April 2024

Our customer already had a short version of the feeding station (AU2-MNK-UTR), but for space reasons he needed another machine that was perfectly tailored to his (space-related) requirements. Here you can read how we proceeded with this customised solution:

1. New measurement and adjustment of the frame base plate: We began by re-measuring and adjusting the frame base plate so that the newly manufactured parts could be installed without any problems.
2. Base hole and threaded holes: New holes were required to make the adjustments and fit the machine perfectly.
3. Removal of side straighteners and other parts: In order to achieve the desired dimensions, side straighteners and various other parts were removed to create space and optimally adapt the machine.
4. Shortening the machine: After ensuring that all the required parts were available, we shortened the machine according to our customer's requirements.
5. Adaptation and installation of the protective panelling: The protective panelling was carefully adapted and installed to ensure the safety and functionality of the machine.
6. Functional test under simulated production conditions: Before we handed over the machine to our customer, we carried out a thorough functional test under simulated production conditions to ensure that it worked perfectly.

#CustomerService #IndividualCustomisation #Efficiency #QualityGuarantee #FeedingStation

March 2024

Recently, we were faced with an exciting challenge: our customer was looking for a solution for their Ferag unwinding station and its merging, whose servo controllers had been discontinued. We are experts in the procurement and repair of discontinued electronic components. Of course, we found a way to keep the machine running permanently!

After a thorough analysis and cost calculation, we decided to replace the drive controllers and the entire PLC. How did we proceed?

First, the unwinding station was dismantled and transported to our service centre. There, the new mounting plates were fitted outside the machine. Our electronics experts then replaced the entire interior of the control cabinet and restored the wiring to the machine.

But that was not all! As part of its modernisation, the machine was overhauled, the 7-inch display was replaced with an impressive 10.4-inch display, and additional monitoring functions such as a safety PLC were implemented.

Before delivery, the machine underwent extensive testing under production conditions to ensure maximum reliability.

The result? Not only has the maintenance of the unwinding station been ensured, but electronic wear parts have also been reduced, making the machine more fail-safe and robust overall. The newly integrated software also enables our service team to carry out remote maintenance and significantly improves ease of operation and maintenance.

The successfully completed retrofit is further proof of our mission to modernise the production landscape and make existing systems fit for the future.

#RetroFit #Innovation #ProductionOptimisation #ElectronicsUpgrade #UnwindStation

February 2024

Our customer already has a top roller feeding system from Muller Martini and now wants to use it for his Ferag machines too. No problem for the unbeatable MakroSolutions team! We found the perfect solution: An ingenious combination of a used Muller Martini unwinding station, a Ferag SDB (shingle turning belt) and a Ferag LAT (layer indexer) - customised for maximum efficiency and performance. 

The progress so far? We have thoroughly cleaned all the machines, carried out a detailed condition analysis and have already ordered all the necessary spare parts. We are currently in the process of replacing defective parts and resetting the machines to their basic mechanical settings.

What's special about MakroSolutions? We offer an all-round carefree package! Next step: The electrical cabling and parameterisation.

January 2024

We are pleased to tell you about our current project: the extensive remodelling of an entire mailroom!

Our aim was to optimise existing systems and bring them up to date without affecting ongoing operations. A real challenge that we mastered with pride.

MakroSolutions took over the entire project planning, provided our experienced team and organised the necessary materials. We also customised and redesigned some of the machines to meet individual customer requirements in order to increase efficiency.

What did we do specifically? We rebuilt and relocated two existing Ferag lines.  In addition, we replaced two used Ferag lines with 2 Schur lines. Furthermore, we converted an SNT combination to "hanging transfer", supplied a modified Ferag delivery station, adapted the removal of the SNT and supplied a newly designed vacuum belt.

The result? A modernised mailroom that works smoothly and efficiently and meets the highest requirements. We are proud of our team and look forward to more exciting projects!

#MakroSolutions #Innovation #Remodelling #DispatchRoom #Efficiency #ProjectManagement #Teamwork

November 2023

Digitise your production and rely on Industry 4.0 solutions! Together with MakroSolutions and Harns Technologies, you can tap into the opportunities of the fourth industrial revolution.

The fourth industrial revolution brings certain challenges and at the same time offers a wide range of opportunities for successful value creation. The aim of the Industry 4.0 concept is to optimise production processes using state-of-the-art, data-based machine-to-machine communication and human-machine interfaces.

Centralised dashboards in the era of Industry 4.0 are convenient and efficient at the same time by bundling production management in one place. They are more than conventional analysis tools for error reduction and process monitoring, as they integrate the Internet of Things (IoT), promote human expertise and increase productivity. The associated flexibility and dynamic customisation options in production management create clear competitive advantages.

With its centralised "Alaiv" dashboards, Harns Technologies offers maximum streamlined data collection and data visualisation in real time.

The centralised, intuitive dashboards from Harns Technologies are industry-leading digital tools because they form extremely effective human-machine interfaces for agile value creation. You can bundle all your production process data within one application and visualise it in real time. Based on the comprehensive insights gained with the "Alaiv" dashboards, you will be able to derive the right technical and business conclusions for highly efficient and economically optimised operation of your production plant more than ever before. The centralised dashboards thus enable a shift from reactive to proactive strategies. This not only prevents potential problems, but also optimises the overall performance of the machine or production plant.

Harns Technologies is an industry leader in Industry 4.0 digitalisation.

Our software partner Harns Technologies offers industry-leading AI-integrated technologies, IoT, data analytics, machine learning and cloud computing solutions for workflow automation, predictive maintenance and labour optimisation as "the next big thing". Use your valuable machine data with Industry 4.0 applications for critical analyses of production processes, machine efficiency, downtime, energy consumption, resource utilisation and much more.

Find out more about Harns Technologies and the Alaiv dashboards at: harnstech.com/cobrand

November 2023

At MakroSolutions, we prioritise quality and ensure that every machine that leaves our premises is in top shape!

We recently acquired a Ferag winding station (MTD) and are currently refurbishing it for a customer. Our experts have already done a great job::

• New belt
• New brush
• New cover for the DTR drive (to protect against paper dust)
• New meshing protection
• And that's not all! Before a machine leaves our premises, it undergoes a thorough inspection and cleaning. We do our best to ensure that every machine works optimally when it lands in your hands.

#MakroSolutions #MachineQuality #ProcessOptimisation #FunctionalTesting #QualityAssurance

October 2023

Successful completion of the SNT-U cutting drum overhaul:

We are pleased to announce that the overhaul of our cutting drum has been successfully completed!

A lot has happened again in the last 2 weeks to make sure our machine is in top shape. Here are the highlights:

• Sensors and actuators put through their paces: Every sensor and actuator was thoroughly tested and defective or worn components were professionally replaced. Perfect function is our top priority!
• Pre-configuration for integration: Our machine was prepared for seamless integration. The settings were optimised to ensure smooth cooperation with other equipment.
• Safety first: We made backup copies of all controls to ensure that our machine works reliably, even in the unlikely event of a problem.
• Precise adjustment of the upper knives: Our team has perfectly calibrated the upper knives on the adjustment table to ensure precise and high-quality cuts.
• Adjustment of the cladding parts: The outer casing of our machine was adjusted and assembled to not only look good, but also function optimally.
• Comprehensive functional testing: We have subjected our cutting drum to a thorough functional test to ensure that everything is running smoothly.
• Ready for shipment: After all these steps, the machine has been carefully prepared for shipment to the customer and is ready to do its job!

We are proud of the commitment and professionalism of our MakroSolutions team that made this success possible. Many thanks to everyone who was involved in this project!

#success #teamwork #precision #functiontesting #innovation #qualityassurance

September 2023

Training of our employee at the market leader WestRock Packaging Systems:

In the largely automated production lines of the packaging manufacturing industry, there is an enormous variety of machine types and machine generations in use. No two machines are alike. This and the constant further development on the hardware side, where every new machine is equipped with the latest automation technologies, places high demands on the knowledge and skills of the plant technicians deployed in the field.

For MakroSolutions it is clear: If you want to "stay on the ball" here, you have to drive the constant improvement of the qualifications of your technical staff.

During a training course at the WestRock Training Centre in Chateauroux, France, our colleague Marcin now had the opportunity to familiarise himself with the company's products and tool types, to expand theoretical knowledge and to practise practical work as a service technician at the control level. This qualifies MakroSolutions in the field to professionally realise orders for plant repair and maintenance for WestRock according to their standards in the future.

Here is the experience report of our Polish colleague Marcin:

"For MakroSolutions I was on site in France for 5 days to develop new knowledge and skills for the products and services of the equipment manufacturer WestRock, together with representatives of international branches. The objective of the "Field Service Cluster-Pak® level 1" training was to be able to maintain and configure the Cluster-Pak® packaging machines used by well-known beverage brands such as Pilsener Urquell or Rauch Fruchtsäfte at the customer's site according to specifications and consequently to enable an optimal and efficient operation of the system on a permanent basis.

The training started with an introduction to WestRock's products such as Cluster-Pak®, Duodozen® and Basket Wrap®. On the second day, we were introduced to different generations of WestRock equipment and their most important electromechanical and electrical components. The mechanical construction of a Cluster-Pak® machine and the handling of its control panel were intensively discussed and trained on the third day. Under the guidance of the instructor, we learned how to download and change parameters for the servo drive. The visit to the production facility in the new WestRock plant as the highlight of the fourth training day presented us with state-of-the-art safety systems and solutions for servo drives and product tracking processes. Finally, on the last day, the participants repeated the knowledge they had gained and we were provided with additional training materials.

In summary, it was an extremely interesting training. For both the intensive familiarisation with the specifications of the WestRock packaging systems and the presentation of the latest components from Rexroth-Bosch, B&R, Keyence, Sencon, Yaskawa and Allen-Bradley used in the machines are exciting gains in experience for being able to implement the maintenance and updating of the WestRock automation systems in practice."

#IndustrialAutomation #WestRock #ClusterPak #Qualification #Training #RetroFit #PlantAssembly #PlantRepair