Project overview

Zejatech completed a retrofit of a vertical Maplan rubber injection molding machine by replacing the original obsolete control system with a modern KEBA control platform.

The machine, originally manufactured in 1995, was upgraded to improve production reliability, machine control, and process stability for a customer in the automotive industry.

Instead of replacing the machine, the customer chose a control system retrofit, extending the lifetime of the machine and adapting it to current production requirements.

Machine specifications

Manufacturer: Maplan

Machine type: Vertical rubber injection molding machine

Year of manufacture: 1995

Clamping force: 4000 kN

Industry: Automotive 

Scope of retrofit

The retrofit included the following activities:

   -> Replacement of the original obsolete control system

   -> Installation of a new KEBA control system

   -> Installation of a new operator panel

   -> Development of a custom control application

   -> Implementation of a new user interface

   -> Adaptation of machine functions to customer production requirements

   -> Commissioning and machine testing

   -> Process optimization

   -> Additional system extensions

Challenges

The machine was almost 30 years old, with an outdated and unsupported control system.

The main challenges included:

   -> replacing obsolete electronics

   -> adapting the machine control to modern production requirements

   -> maintaining compatibility with the existing hydraulic and mechanical systems

   -> implementing customer-specific production functions

Results

After the retrofit, the machine now operates with a modern and reliable control system.

Key benefits:

   -> improved machine reliability

   -> easier maintenance and serviceability

   -> modern user interface

   -> improved process control

   -> better production stability

   -> reduced downtime

   -> long-term spare parts availability

The retrofit allowed the customer to extend the lifetime of the machine while improving production efficiency.

Technology used

   -> KEBA control system

   -> Custom machine control application

   -> New operator interface 

   -> Zejatech engineering and commissioning

Our solutions extend machine lifetime while improving reliability, automation, and production performance.