1 | 08.02.2024 KILIAN Services Mechanical / Electronical Retrofit / E-Upgrade / Segment technology
Agenda • Romaco Kilian in Cologne • Why go for original KILIAN? • Common KILIAN bestsellers from the past • Mechanical Retrofit & Overhauling • Overhauling made @ KILIAN - A special case, KILIAN RX within one week • Overview Mechanical Retrofit & Overhauling • Electronic Retrofit - Upgrade to state-of-the-art technology and performance • Hardware upgrades & Software updates • Overview Electronic Retrofit / Hardware upgrades & Software updates • Remote Assist • Segment Technology
Romaco KILIAN in Cologne, Germany Modern manufacturing plant build 2005, workplace for 194 highly motivated & skilled employees Return
Retrofit / Overhauling / Upgrade • Exact planning and professional project management → shortest possible downtime • Analysing of components for re-use → cost reduction • “Surprise parts” can be produced in KILIAN factory → less downtime risk • Original manufacturers knowhow and experience in original drawings and machine → • Better reliability • Higher performance • Less product loss of retrofitted machine in daily production environment. • Full warranty & access to full KILIAN support → higher uptime • Upgrade of components to latest version of new machine design • KILIAN well-known HMI software structure remains (include self optimizing controller) • Further OE Service via KILIAN After Sales available • Remote Assist for online trouble shooting & support available Why go for original KILIAN? Return
Retrofit / Overhauling / Upgrade Common KILIAN bestsellers from the past RTS (1994 - 1998) T100 (1995 - 2009) S100 (1995 - 2005) T200 (1994 - 2005) E150 (1997 - 2007) T300 (1994 - 2006) S250 (1996 - 2004) T400 (1994 - 2008) RX (1981 - Today) Synthesis (2002 - ) Return
KILIAN Services Mechanical Retrofit & Overhauling Return
Mechanical Retrofit & Overhauling • Scratches on the die table surface • More product loss • No correct function of the brake pins • More weight deviations • Worn out punch shaft bores • Increased wear on the punches • Damaged pressure rollers • Dramatically increased wear on the punches • Dirty and worn out cam track • Increased wear on the punches • No safe functioning lubrication system • In general more wear • High failure risk, jeopardized production Why retrofit or overhauling? No unplanned down time Reduced product loss Less weight deviations Return
Mechanical Retrofit & Overhauling 1. Preliminary inspection on site by KILIAN technician (MQ) 2. Preliminary analysing of components/parts which can be reused 3. Quotation phase and purchase order 4. Manufacturing and acquisition 5. Delivery of machine to KILIAN 6. Professional cleaning with external company 7. In house analysing of components which can be reused 8. Overhauling and repair of machine incl. final FAT 9. Shipping of machine to customer 10. Re-commissioning by KILIAN technician Project plan Typical 3 weeks duration Depending on retrofit effort KILIAN Project Management Shipping to customer Overhauling & Repair Delivery of machine Manufacturing & Acquisition Quotation & Purchase order Analysing of components Analysing of components Professional cleaning 1 2 3 4 5 6 7 8 9 10 Preliminary Inspection Re- commissioning Return
Replacement of following parts: • Die table with KILIAN patented brake magnets and optional punch bellows (if required) • Upper and lower cam track • Long lasting pre- and main-pressure rollers including eccentric bolt and bushing • Lubrication system including low-maintenance lubrication pump • Fill shoe drive, state-of-the-art (if required) • Main drive, state-of-the-art main drive (if required) • Clutch and belt for main drive • Vertical shaft • All wear parts like bearings, sealings etc. • Spare part documentation Overhauling of following components: • Fill shoe include new bearings, pulleys, belt, sealing segment, scrapers, springs etc. • Dosing unit including new synchro drive Mechanical Retrofit & Overhauling Overhauling made @ KILIAN Return
Mechanical Retrofit & Overhauling • Special closed punch bellows (for dedicated models optionally available) • No BLACK SPOTS • Reduced wear • Less cleaning effort • Low vertical wobble • Reduced product loss Overhauling made @ KILIAN - Original KILIAN die-table • Unique brake magnets • Less weight deviations • Maintenance-free • No heat generation • Faster installation of compression tools • Less cleaning effort • Special coatings for die table plate available • Avoiding corrosion • Reduced wear especially when working with abrasive products Knowhow Experience Precision Performance & Reliability Return
Before overhauling After overhauling Mechanical Retrofit & Overhauling Overhauling made @ KILIAN - Example KILIAN TX40 The old lubrication pump was replaced for easier access and less maintenance. Return
Original parts • Guarantee the full functionality of the tablet press • Durability and longevity due to the appropriate material choice • Reduced product loss due to high precision • Availability – KILIAN standard stock parts Mechanical Retrofit & Overhauling Overhauling made @ KILIAN Return
Before overhauling After overhauling Mechanical Retrofit & Overhauling Overhauling made @ KILIAN - Example KILIAN T 400 Even the punch pass sensors including cables and plugs have been changed compared with the up-to-date stock version. Return
Mechanical Retrofit & Overhauling A special case, KILIAN RX within one week Day 1, professional cleaning with external company Day 2, partial disassembly Day 3, complete disassembly of machine and 2nd inspection if parts which can be used again, overnight production of additional parts required Return
Mechanical Retrofit & Overhauling A special case, KILIAN RX within one week Day 4, installation of lower cams and die table Day 6, installation of head piece Day 5, piping & wear parts replaced Day 7, customer FAT & Day 5, installation upper cams & housing preparation for shippingReturn
Mechanical Retrofit & Overhauling Possibilities for partial overhauling on site • Replacement of die table plate incl. replacement of eccentric bolt and bushing • Exchange of pressure rollers and bearings • Gearbox repair or replacement • Hydraulic system • Vertical shaft, function key and speed bushings • Replacement of WSG • Lubrication system • Replacement of fill shoe drive Worn cam track → more wear on the punches Scratched die table plate → more product loss Damaged rollers → more wear on the punches Return
Mechanical Retrofit & Overhauling Conversions • Conversion to other tool standard (e.g. EU-D to EU-B) for machines without interchangeable die table. Includes new die table, cam tracks, new spare part documents etc. and can also be done on site. • Increased tablet output • New tablet format • Upgrade from Mono to Bi-layer version, including modified cam track, die table, lower part of fill shoe housing, new product scarpers and modification of extract system (for Synthesis 700). Existing machines are already prepared for Bi-layer production • Existing machine is already prepared for Bi-layer production • New application • Flexibility Mono-layer Bi-layer Upgrade Conversion to other tool standard Return
Mechanical Retrofit & Overhauling • Short down time • Shortest possible down time due to exact planning and professional project management, typical 3 weeks (depending on retrofit effort) downtime period • If additional damaged parts will be located during the repair, we can produce them immediately if they are not on stock • Also, shorter repair periods possible, see example • All relevant wear parts on stock • Reliability • Better reliability because of choosing the best quality material for the application • Precision for an exact guiding of the punches and therefore reduced wear • Performance • Reduced weight deviations because of brake magnets • Less product loss because of reduced vertical wobble • OE services • Lifecycle extended, full future spare parts support by KILIAN • Full warranty when using original KILIAN spare parts • Remote service • Automatically upgrade to the latest or better mechanical version • Investment is starting from 20-30% of a new machine • Optional electrical Retrofit with latest version HMI-system Benefits Return
Mechanical Retrofit & Overhauling Return
KILIAN Services Electronic Retrofit / Hardware upgrades & Software updates Return
Situation: • Certain electronic spare parts for machines like RTS, S100, E150, LX, S250, TX, RX, T100, T200, T300, T400, and Synthesis are/will be obsolete • Especially the control systems cannot be supported any longer with spare parts • The only option remaining is repair, if this is possible at all. This typically leads to long delivery times. • Older software e.g. SIEMENS PLC cannot be supported any longer Electronic Retrofit The impact of obsolete spare parts Impact: Long delivery times resulting considerable down times of the equipment, possible jeopardizing production and revenue Obsolete Obsolete Obsolete Return
Electronic Retrofit Concerned machine models Obsolete machine control & operating panel Operating panel - push buttons Machine control - contactors Operating panel - MT80 Operating panel - Siemens OP7 PLC - Siemens S5 PLC - Siemens S7-200 (for example T100, E150, LX, TX) (for example T100, T300, T400) (for example E 150 Plus, S250) Return
Electronic Retrofit Concerned machine models Obsolete control systems (HMI) MC (1982 – 1996) A100/CW100 (1985 – 1999) C30 (1995 – 2005) C50 (DOS based) (1994 – 2007) ViCon V1.0 (1999 – 2003) C50V (WINDOWS) (2002 – 2012) Return
Electronic Retrofit Electronic retrofit kit, upgrade to latest technology and best possible performance Operating panel Siemens OP7 PLC Siemens S7-200 C50V (WINDOWS) KILIAN Electronic Retrofit kit Obsolete Technology State-of-the-art technology Operating panel push buttons Machine control contactors Operating panel MT80 PLC Siemens S5 C30 A100/CW100 +++ Retrofit Ensures reliable operation as well as the possibility of additional functions and features. Control system Return
Standardised solution with state-of-the-art components used on our latest machine generation. • Stainless steel execution provides IP54 protection rating • BACHMANN M1 PLC-System or SIEMENS frequency converters The standard (4 m) cable length can be increased up to 25 m if the cabinet is to be located outside the compression room. Dimensions: Height: 1800 mm Width: 800 mm Depth: 500 mm Electronic Retrofit New external control cabinet Return
The simple and user friendly “Vision” software with its well known menu structure allows easy handling of the press after basic operator training. • Latest Windows version • 21’’ touch screen • PC and monitor are mounted into a modern movable stand with pluggable connections • Prepared for 21 CFR Part 11 • Unlimited number of production pre-sets • Network connection as standard • Prearranged for remote assist • Data transmission to TCU unit optionally available • Additional options like Human RQ or Trending Software available • Paperless production as standard, including: • Batch end report • Operation messages • IPC data report • Audit trials (option) • Set up data report • Cyclic production report • Compaction force statistics Electronic Retrofit New external HMI (Prime version) Set-up screen Batch Report Separated control panel Return
The simple and user friendly “ViCon” control system allows easy handling of the press after basic operator training. • Newest Windows version • 19’’ touch screen • Monitor and PC mounted in a separate stand • Paperless production as standard • Audit trials optional available • Network connection as standard • Prearranged for remote diagnostic Electronic Retrofit New external HMI Set-up screen Batch Report Separated control panel Return
Electronic Retrofit Installation process (can be done at customer’s site or at KILIAN) • Removal of all electric components from the existing control cabinet • Installation and connection of a new terminal strip with connection box • Removal of old HMI, opening closed by cover • Connection of machine and new external control cabinet with the cable beam • Connection and configuration of new external HMI • Typical installation time: 3 weeks (depending on retrofit effort; IQ/OQ included) New terminal strip mounted on T400 Cover plate to replace control panel on T400 Illustration of connection box on T400 On site installation 3 weeks conversion time (or even shorter) Return
Electronic Retrofit Re-qualification Complete set of IQ/OQ-documents for the Re-qualification of the electronic retrofit kit available. Return
Electronic Retrofit 1. Purchase order 2. Manufacturing & Acquisition of components, preparation of documentation etc. 3. Shipping of goods 4. Installation on site via KILIAN technician 5. Commissioning & Training 6. Validation (IQ/OQ) 7. Production support for the rest of the machine life cycle (Remote assist possible) Project plan Purchase order Validation Commissioning & Training Installation on site Shipping of goods Manufacturing & Acquisition Production support Typical conversion time 3 weeks Depending on retrofit effort KILIAN Project Management 1 2 3 4 5 6 7 Return
Some machines like our T300, T400 or Synthesis are already equipped with a Bachmann M1 PLC-system and our ViCon control system. In these cases, it is only the control system that we will not be able to support with spare parts in the near future. If you would like to have more certainty regarding future spare part availability or like to have the same look and feel as on our newer/latest machines, we have a solution for you. Hardware Upgrades & Software Updates Better spare part availability Same look and feel Return
Hardware Upgrades & Software UpdatesEnsures a more consistent spare part availability, offers the same look and feel like newer KILIAN machines include possible additional functions and features. Hardware upgrades + Past Technology State-of-the-art Technology + Bachmann M1 PLC-system Industrial PC Bachmann M1 PLC-system HMI - ViCon V1.x (integrated PC) HMI - ViCon V3.02 (15“ Touch Panel) Bachmann CPU, WSG-Module, Fastbus-Card etc. UPS Industrial PC HMI – V4.0 19“ Touch panel (Windows) Re-Qualification Upgrade (For example T300/T400 or Synthesis) Return
E-Upgrade ViCon V4.04 Old ViCon software V2.04 • Designed for 15“ monitor • Touch screen function Old ViCon software V3.08 • Designed for 15“ monitor • Touch screen function • Self optimizing controller • Set-up screen shows tableting process Upgrade to ViCon software V4.04 • Designed for 19“ monitor • Touch screen function • Self optimizing controller • Set-up screen shows tableting process • Based on latest Windows version • Explorer style menu design • Print screen button (option) • Human RQ (option) • Trending (option) • Machine control buttons integrated Hardware upgrades & Software updates Upgrade Upgrade Old ViCon 2.04 Old ViCon 3.08 ViCon 4.04 Please note that for some upgrades hardware changes may be required! Return
The Hysteresis is calculated automatically when entering the tolerance values and the regulation step-length is calculated during the set-up phase. Advantages: • Wrong inputs are avoided (too large, too small or even out of the tolerance limits) • Time saving during set-up • Better quality of production • Parameter reduction The optimising process is done inside the tolerances or production limits, no bad tablets will be produced. E-Upgrade ViCon V4.04 Self optimising controller * Forces measured via WSG No wrong inputs Faster set-up Quality Return
E-Upgrade ViCon V4.04 The simple and user friendly HMI ViCon visualisation software allows easy handling of the press even for unskilled operators. • 19‘‘ touch panel • Self optimizing regulation system • Prepared for 21 CFR Part 11 • Unlimited number of production pre-sets • Network connection as standard • Prearranged for remote diagnostics • Data transmission to IPC unit (optionally available) • Paperless production as standard, including: • Batch end report • Operation messages • IPC data report • Audit trials • Set up data report • Cyclic production report • Compaction force statistics Control system / HMI ViCon HMI-ViCon Set-up screen Return
All messages (error, status, audit trial etc.) in one screen Detailed compaction force graphics E-Upgrade ViCon V4.04 Return
E-Upgrade ViCon V4.04 Tablet check unit for measuring of weight, thickness, hardness can be connected to the machine. The measured tablet parameters will be displayed on the HMI and shown up also at the batch reports. Different tablet check units (TCU) are optional available. Software for data transmission IPC (optional) Return
E-Upgrade ViCon V4.04 Tablet weight can be measured on an external remote device. Manually entered data is used for automatic weight adjustment. No need to enter the set-up mode: no production loss. Human RQ (optional) Return
E-Upgrade ViCon V4.04 Process Transparency Trending is an option to allow the customer to monitor his batches throughout the whole production process at any moment and even after the batch has been ended. Straight forward Display The changes of different parameters (compaction force, fill depth, weight,…) can be displayed in a graph in comparison with the set points given for the product. Flexible Display on demand Multiple extra information can be displayed in this graph such as min./max. values, standard relative deviation (Srel), averages,… Trending (optional) Return
E-Upgrade ViCon V4.04 Re-qualification Complete set of IQ/OQ-documents for the Re-qualification of the Electronic Retrofit Kit available. Return
Hardware Upgrades & Software Updates Kilian HMI • New state-of-the-art control system • Based on latest Windows version • IQ/OQ documentation for Re-Qualification available • New electrical/electronic components • Same look and feel like other KILIAN machines because of well established and • familiar software structure, only minimal training for HMI needed OE services • Lifecycle extended, full future spare parts support • Future support via KILIAN • Already ordered mechanical spare parts could be used Remote assist • Remote assist (option) for inline failure analysis and faster trouble shooting Optionally a mechanical overhaul and conversion Benefits Return
Electronic Retrofit / Hardware Upgrades & Software Updates *1 Modification base plate needed, only @ KILIAN , *2 Just for machines with ViCon HMI Return
Retrofit / Overhauling / Upgrade With the optional “Remote assist” it is possible to connect to the HMI or PLC-system. Due to the super user access, we have instant access to the relevant machine parameters and any current error messages as well as to internal system data for diagnostics. This saves valuable diagnostic time, and the service engineer can set to work, finding a solution without delay. The support platform provides secure data transfer, so that customer requests for assistance can now be processed efficiently. • No time loss due to travel time • No unclear failure description • In-time failure analysis • No travel expenses for technical intervention • Online software updates possible Remote assist Open VPN Open VPN Connected machines (outside customer network) Hotline Romaco server Customer Return
We thank you for your interest!