From Obsolete to Reliable: Rubber injection molding machine Retrofit with KEBA Control
One of the biggest challenges with older injection molding machines is their obsolete and unreliable control systems. When the electronics become unstable, production suffers – downtime, inconsistent processes, and rising maintenance costs.
That’s why we carried out a complete control system replacement on several vertical rubber injection molding machine (year 1998 - 2011, 4000 - 6000 kN clamping force).
What we did:
Replaced the outdated control with a state-of-the-art KEBA industrial control system
Developed a new customer application and user interface, tailored to production needs
Fully commissioned the system to bring the machine back to stable production
The result:
Reliable and stable production for the automotive sector
Extended lifetime and productivity of an otherwise fully functional machine
Reduced downtime and risk thanks to proven KEBA technology
With this retrofit, the customer transformed an aging press into a modern, production-ready asset – proving that the right control system makes all the difference.
Successful Retrofit of the additional Windsor Injection Unit!
We’ve just completed a retrofit of secondary Windsor injection unit – giving new life to an older machine through smart upgrades.
Old B&R system replaced by new Keba control system CP056Y and new 18" operating panel.
Type: Windsor WKT4
Year of production: 2001
Automotive
Location: Germany
Keba control system installation on 15 vertical vulcanization rubber injection molding machines REP
Some projects need to be completed quickly and as cheaply as possible. Or when there's no time for heroism.
Just integrate the new system into the original cabinet, put it into operation and start production.
Basic economical retrofit with cheaper version of Keba control system.
Year of construction: 1988 - 1996
Typ: different types
Clamping force: 1000kN - 4000kN
Automotive
- new Keba control system installation
- on some machines also Servo pump installation
- new customer control application and user interface based on customer requirements
Wickert WKP 5000, Ettlinger SRM 100 SE, Laufer
After large, complex projects, a bit of a return to the roots.
Retrofitting of several compression molding machines from the last year.
Keba control system installation and application development with multiple extensions and improvements.
Machines: Wickert WKP 5000, Ettlinger SRM 100 SE, Laufer
Compression molding machines
Year of production: 1990s
Location: Germany, Spain, Czech Republic
Many thanks to my colleagues Sebastian Meindl (www.ets-meindl.de) in Germany and Josép María Alvarez (alvarezjosepmaria@gmail.com) in Spain for great cooperation.
And also excellent company Raorsa (www.raorsa.es) who takes care about the Spanish project.
We sent another original Engel controller to technical museum and install the new Keba control system instead
Retrofit of special unique Engel ES18000/1200C assembled especially for several kilo PVC fittings production.
Imortal Engel machine from 1987 with very low maintenance care, retrofitted with Keba system, still produce the 15-20 kilo PVC fittings.
Type: Engel ES18000/1200C
Year of production: 1987
Location: Slovakia
For a change, I would like to present retrofitting of several smaller classic injection machines, which we renovated last year
There are some situations when it makes sense today to retrofit and adjust also smaller horizontal injection machines (not only big, vertical or somehow special inj. molding machines, which we ussually retrofit).
If you don't get what you need from the IMM suppliers, you can retrofit an available older or new injection machine. Install new control system with your custom application. Simply adjust machines exactly according to your requirements.
Several Engel ES machines retrofitting - new Keba control system installation, additional mold heating and commissioning with inverters:
Engel ES700/175
Engel ES700/100
Engel ES200/350
Engel ES330/90HL
Engel ES330/110H
Hemscheidt 1400/400 HL retrofit
Special key parts production from Germany.
Hemscheidt 400HT retrofit. Obsolete Siemens replaced by new Keba controller and extensional modules.
Type: Hemscheidt 1400/400 HL
Year of production: 1995
Clamping force: 4000 kN
Location: Germany
Included cabinet renovation. Customer application. OPC UA interface.
Keba system installation on new PAN STONE Inj-500/4000
Improvement of another Pan Stone rubber injection molding machines.
Exchange of original Fuji controler by new Keba systems. Application adjustement to specific customer production and quality control management.
Year of construction 2020
Model: PAN STONE Inj-500/4000-A-FIFO
Clamping force: 5000kN
Automotive
Location: Morocco
Automotive
The goal of customer is to purchase the machines with the cheapest basic controller and adjust and tune the machines to his specific production requirements.
Battenfeld BA10500 Keba Retrofit
Obsolete original Schleucher system replaced by new Keba controller and extensional modules.
Complete controller exchange included mold heating zones, valvegate control, robot interface, inverter control, second injection unit interface, ...
Type: BA10500
Year of construction 1992
Clamping force: 10500 kN
Location: Spain
Automotive
- obsolete control system exchanged by new Keba controller
- mold heating zones, valve gates, Euromap interface
- interface for external second injection unit
- all components and movements programmable in machine sequencer
- programming of custom application specialized for automotive production and quality control
Fahrbucher TS160P - Keba machine retrofit (Replacement of the original control system)
New Keba system installation included new cabinets in very specific area of duroplast parts production
In addition, the customer decided to install servo pump
Application optimisation for duroplast production
Type: TS160P
Year of construction 1997
Clamping force: 1600kN
Location: Germany
- controller exchange (Keba controller installation)
- servo pump installation
- implementation of new customer requirements for duroplast parts production
- commissioning and test in production
LSMtron LS1050s and LS350d - Two platen IMM and direct clamping - Keba retrofit
Controller exchange, Keba controller installation and machines commissioning
Type: LS1050s - 2 platen injection molding machines and LS350d direct clamping
Year of construction: 2010, 2011
Clamping force: 10500kN and 3500kN
Location: Russia
Automotive
Unfortunately, probably the last project in Russia for some time.
- Controller exchange
- Keba controller installation
- implementation of new customer requirements
- commissioning and test in production
- 2 machines LS1050s and LS350d
TAYU TY550-2R Vertical / Keba system installation instead of original Siemens controller
Fast economical retrofit of another vertical injection molding machine in Germany
Type: TAYU TY550-2R Vertical
Clamping force: 550 kN
Year of production: 2009
Location: Germany