Examples of applications in special machinery
Our specialist machines are used in a variety of industries. From the automotive industry to medical technology, we develop machines that are precisely tailored to your processes and products.
Special machines construction and automation
As unique as your business.
We specialise in innovative, custom-designed solutions for special-purpose machine construction, manufactur in Konstanz on Lake Constance. As a full-service system supplier and integrator, we combine expertise in mechanical engineering, automation engineering and manufacturing to create unique special-purpose machines tailored precisely to your requirements. Our portfolio ranges from simple semi-automatic machines and retrofits to complex, fully automatic assembly machines and assembly lines. Together with our customers, we develop the optimal solution for on-site production and commission the processes according to your requirements.
Why choose k-tech?
➤ Everything from a single source - fewer interfaces
➤ Over 35 years’ experience in the manufacture of specialised machinery
➤ Cross-industry expertise
➤ Flexible solutions
➤ High depth of value creation
➤ Support throughout the entire lifecycle
➤ Everything from a single source - fewer interfaces
➤ Over 35 years’ experience in the manufacture of specialised machinery
➤ Cross-industry expertise
➤ Flexible solutions
➤ High depth of value creation
➤ Support throughout the entire lifecycle
#ansprechpartner
Let’s analyse your requirements together
750
projects completed worldwide
625
successful customer partnerships
20
International reference projects
Fixture manufacturing
Fixtures are the simplest assemblies in our range. They are characterised by a high degree of manual operation, with only a very small proportion of automated processes. Their main purpose is to assist the operator during inspection, measurement, adjustment and assembly processes.
Semi-automatic custom machine
With this type of machine, the operator is still very much involved in the manufacturing process and usually remains at the machine at all times. They are generally responsible for manually loading and unloading components, as well as for tasks that cannot be automated for cost-effective reasons.
Assembly machinery
With this type of machine, the operator is primarily responsible for loading and unloading materials. Typical tasks include filling storage hoppers with bulk material, as well as manually feeding and unloading stacked blister packs, small load carriers (SLCs) or magazines. Economically viable autonomous operating times for the system range from approximately 1 to 8 hours.
Production lines
Production lines typically comprise a series of interconnected machines. Transfer systems with workpiece carriers are often used to connect these stations. The machines are usually modular in design, and some are equipped with their own control systems. This ensures maximum flexibility. Such systems are often supplemented by manual workstations that are connected to the transfer system.
Automated Handling
In mechanical engineering, automated handling refers to the planned and controlled movement of workpieces, components, or materials within manufacturing and automation processes. This encompasses typical operations such as gripping, loading and unloading machines, positioning, separating, feeding and pick-and-place sequences. Depending on the requirements of the process, we use cost-effective pneumatic axes, or high-precision, camera-assisted robotic systems if absolutely necessary.
Retrofit
Many of our customers continue to rely on tried-and-tested, highly functional machines, which are often unique systems for which it would be neither economical nor technically feasible to purchase new ones.
Our services in this area include:
- complete modernisation of control systems, software, electrical systems, cabling and pneumatics
- replacement of mechanical and mechatronic components (motors, bearings, cylinders, etc.)
For many customers, the issue of occupational safety is becoming an increasingly important focus. We therefore also retrofit the relevant safety technology to existing machines.
Our applications
in custom machine construction
We offer everything from individual workstations to fully automated systems.
We design and build workstations, compact and medium-sized plant modules, and fully automated production lines in an efficient and practical manner
Feeding
- Input and output stations
- Feeding, separation and sorting systems (including micro-components)
- Conveyor lines
- Packaging and palletising systems
Handling
- Handling systems
- Pick-and-place systems
- Robotic systems
- Gripper and tensioner systems
- olders and mould cavities
Assembly
- Automated assembly machines
- Assembly lines / production lines
- Modular assembly cells
- Individual assembly workstations
- Rotary indexing machines
Inspection
- Tactile sensors
- Optical sensors
- Capacitive sensors
- Functional testing
- Final inspections/ELO
Our stages in special-purpose machinery manufacturing
We can handle the entire process for you, or just specific parts of it. Our range of custom machine construction services includes:
Planning and consultancy
Brainstorming
The best solution
k-tech not only advises and supports you in the ideation phase, but also in identifying the right solution and implementing it. Our aim is to work with you, our client, to find and deliver the ideal solution for your project.
We would also be happy to advise you on other areas within our portfolio.
Project management
Structure is key to success
k-tech brings together all the engineering expertise and resources you need under one roof. This means that we can take charge of the planning and project management right from the outset.
We use our in-house project management tool to plan the entire process and ensure the project runs smoothly.
We provide regular internal and external project updates. This ensures that you, as our client, are always kept informed of the project’s progress in terms of time, technology and budget.
Throughout the entire order process, we also coordinate collaboration with our suppliers.
Procurement
Supply of components
We can handle the entire procurement process for mechanical and electrical components, including custom-made and standard parts, as well as pneumatic and electronic components, cables, and control and drive components, upon request. You will benefit from our network of suppliers and our established framework agreements, which ensure reliable delivery and consistent terms.
Preliminary study
Engineering & product development
Product development and process analysis
Once your product idea has been fully developed, k-tech will be happy to support you with product development and process analysis. Our experts will collaborate with you to devise suitable concepts, analyse processes, and propose solutions. We will implement these concepts in close consultation with you.
In addition to the design phase, we can help you select appropriate manufacturing technologies and materials, and find the right manufacturer for standard components. This ensures that your product is developed efficiently and is ready for the market.
Feasibility study
To safeguard the process for you as a customer and identify risks in good time, k-tech will support you in securing your core process. During the feasibility study, we assess and discuss process optimisations and risks with you, and carry out further investigations where necessary. This step lays the foundation for a successful project.
Conceptual design
During the conceptual design phase, technical, methodological and systematic approaches are documented and evaluated. The key machine components are defined at this stage, as are the core processes. This preparatory work is used to draw up your quotation and as the basis for the subsequent design phase.
Prototype construction
We would be delighted to work with you to bring your ideas to life in the fields of assembly and equipment construction. We support the entire development process, from prototype development through to series production. k-tech can undertake complete or partial prototype construction for you.
In addition to development, manufacturing, assembly and cabling, our team of experts can handle test runs, optimisations, quality assurance reports and documentation.
Mechanics
Calculations
Interpretation of dimensions
k-tech supports you in the design of dimensions, processes, control concepts and components. We also assess the strength of components. We can carry out these design tasks in-house, in collaboration with partners, or with the manufacturer. The various analysis and simulation methods help us to optimise your product and your process flow, ensuring that you achieve the best possible result.
Construction
Systematic approach to detail work
Following the design phase and your approval as the client, the next step is the construction phase. During this phase, we create detailed assemblies and determine which components will be used. In addition to the 3D model, we also produce the corresponding parts lists, assembly drawings, manufacturing drawings, CAD-CAM programmes, EDM programmes, documentation and much more.
For this, we use the following CAD tools:
Autodesk Inventor
SolidWorks
AutoCAD
CNC production
State-of-the-art manufacturing
k-tech relies on CNC-supported manufacturing, with a comprehensive range of CNC-controlled machining centres and lathes. Thanks to our ongoing expansion, we can respond to the ever-increasing demands placed on CNC-machined parts.
Thanks to our CAD-CAM software, Visual-Mill, we have long been designing not only in 2D but also in 3D – the foundation for the development of a modern, associative production process. With the introduction of a new CAD-CAM software called SolidCam, one of the most advanced manufacturing tools on the market has been integrated. By directly adapting it to our existing design programmes, we have been able to create a seamless system.
We can now offer you a direct link from individual components or assemblies to the production machining centre. Design adjustments and changes are reported directly and can be incorporated into the production process. This modern process ensures our quality standards. It is a key component of our quality management system.
To assemble
professional assembly
Our team assembles your mechanical, electrical, pneumatic and mechatronic systems in accordance with drawings, parts lists, assembly instructions, circuit diagrams and cable lists. Depending on your requirements and needs, we produce one-off items, prototypes or production runs.
Automation
Hardware Engineering with EPLAN and WSCAD
Well-designed hardware for your automation
A wide variety of components are used in mechanical engineering: drive technology, pneumatics, sensors, safety technology, camera systems, dosing systems and much more. To connect and power these electrically, k-tech relies on tried-and-tested components and technologies.
With monitored power supplies and intelligent circuit breakers, we ensure the protected and transparent operation of the system. For design and documentation, k-tech uses tried-and-tested planning software such as EPLAN and WSCAD. Using a circuit diagram, it is possible to configure the control cabinet precisely and to locate faults more quickly during troubleshooting.
Benefit from our expertise in automation and work with us to bring your project to fruition.
Future-proof software engineering
Complex systems. Clear solutions.
PLC and HMI programming
Mit Siemens und Beckhoff (Codesys-basierte Benutzeroberfläche) setzt k-tech zwei der beliebtesten und verlässlichsten Steuerungssysteme ein. Bussysteme wie Profinet und EtherCAT lassen sich so unkompliziert einbinden. Mit „Structured Text“ nutzen wir die Vorteile der objektorientierten Programmierung, um auch komplexere Aufgaben effizient und übersichtlich realisieren zu können.
Zur Bedienung der Anlage, Datenverwaltung und Darstellung diverser Statusinformationen erstellen wir in Zusammenarbeit mit Ihnen eine entsprechende Bedienoberfläche (HMI). Zur Anbindung anderer Anlagen und Systeme kommen neben der klassischen EA-Schnittstelle auch OPC-UA oder ein nachrichtenbasiertes TCP/IP-Protokoll zum Einsatz. Auf Anfrage setzen wir für Sie auch gerne weitere Systeme und Schnittstellen ein.
Microcontroller Programming
Sometimes a PLC is not a viable option as a control element, for example due to low voltage levels, lack of space, cost or speed. In such cases, we at k-tech make use of the advantages offered by a microcontroller. In collaboration with an in-house partner, we can develop the necessary hardware for you. Using analogue and digital technology, we can thus meet a variety of requirements on a custom-made circuit board.
Robotics
The use of robots in industry is becoming increasingly important. As k-tech is committed to always being at the cutting edge of technology, we are increasingly using robots from various manufacturers in our specialised machinery. Benefit from our experience in the field of automation: in addition to mechanical integration into the system, we also offer electrical and safety-related connections, robot programming and integration into the PLC. Whether SCARA, 5-axis or 6-axis robots: we are happy to assist you in selecting the right type of robot and the most suitable size.
Partnerships with robot manufacturers
- Epson
- Kuka
- Stäubli
- Nachi
- Mitsubishi
- Universal Robots
- ABB
- Denso
- Fruitcore Robotics
- Others on request
Manufacturing of customised control cabinets
Reliable energy for your plant
Whether for small systems or larger installations: we assemble and wire your control cabinets to your specific requirements. It makes no difference whether the control cabinet is part of a specialised machine or whether you require one or more control cabinets for your own application. Here too, k-tech can support you as an extension of your workshop. Our service includes testing the control cabinets in accordance with the applicable VDE guidelines prior to delivery.
Installation & Commissioning
Installed securely. Started successfully
To ensure that we deliver a machine that operates flawlessly, we carry out a wide range of tests and checks on the interlinked processes. These include both the basic VDE tests to ensure the machine’s electrical safety, as well as general and project-specific functional tests.
Following delivery of the system, we are happy to assist you on site with installation and alignment, commissioning and integration into your infrastructure. Final functional tests ensure the safe operation of the plant and a stable production process.
Security technology
Protection for people and machinery
In order to operate a CE-compliant system, it is necessary to install appropriate safety technology to protect both people and machinery. k-tech can draw on many years of experience across a wide range of safety technology sectors and support you in implementing the optimal safety solution. We develop, install, wire and test the safety system for you.
Partnerships with manufacturers of tried-and-tested safety components
- Pilz
- Elobau
- Ifm
- Schmersal
- Euchner
- Sick
- Beckhoff & Siemens
- Omron
- Phoenix Contact
- Eaton
Documentation
Comprehensive documentation
All the documents. One point of contact.
Our responsibilities include not only the development and manufacture of your product, but also sustainability. To ensure this, in addition to the user manuals, we can also produce operating instructions, lists of spare and wear parts, maintenance instructions, technical documentation covering mechanics, pneumatics, hydraulics and electrical engineering, as well as the necessary software. We also provide you with acceptance test reports, the EC Declaration of Conformity and CE marking.
Analysis & Concepts for Security Solutions
Assess risks. Ensure safety.
Do you need assistance in developing a safety concept, or would you like to take a closer look at an existing one? k-tech would be happy to advise you, because we know that, particularly in the field of safety engineering, safe, efficient and ergonomic working practices must be guaranteed. We are also happy to carry out a risk analysis in accordance with ISO 12100, as well as a machine safety assessment in accordance with ISO 13849 using the “Sistema” software tool.
EC Declaration of Conformity
Compliance with the Machinery Directive
If you are putting a machine into service in Europe, you require a valid EC Declaration of Conformity in accordance with the Machinery Directive (2006/42/EC). In addition to various documents, this also requires a risk assessment in accordance with ISO 12100 and a machine safety assessment in accordance with ISO 13849.
Here at k-tech, we can prepare the necessary documentation for you, including the EC Declaration of Conformity in accordance with the applicable EU directives.
Service, Repairs and Spare Parts
Maintenance prevents downtime
To ensure that your machinery and equipment have a long service life, we recommend that you carry out servicing, inspections and maintenance work. k-tech has its own flexible service team, which will carry out maintenance work at your premises with care and professionalism. Our service team can also maintain third-party equipment and assist you with the procurement of spare parts.
We would be happy to draw up a suitable maintenance contract with you.
We integrate these technologies into specialised machinery.
Connection technology
- Clutching
- Rolling and tumbling
- Joining and pressing
- Crimping
- Bolt
- Screws
- Rivets
- Adhere
- Welding
- Soldering
Dosing
- Fats
- Oils
- 2k and 1k adhesives
- Sealing compount
- Spraying
- Pouring
- Touching application
Machining process
- Flaring
- Bending
- Embossing
- Breaking
- Milling
- Turning
- Drilling
- Cutting
- Punching
- Countersinking
- Sawing
Technical cleanliness
- Suction
- Blow off
- Mechanical cleaning
- Filter
- Airknife cleaning systems
- Rotary cleaning nozzles
- Ionization cleaning
- Electrostatic cleaning
- PCB/PCB cleaning
- Preventing static build-up through ionisation and the use of ESD-compliant materials.
Feeding and Separation
- Vibration pots
- Step separator
- Camera-based robots with vibration systems
- Spring detangling systems
- Pneumatic separation systems
- Drum separator
Buffering
- Stack of inputs & outputs
- Magazine input & output
- Buffer stations and belts
- Parking positions
Transport systems
- Conveyor belts
- Pallet conveyor
- Workpiece carrier
- Rotary indexing tables
- Linear systems
- Link-chain conveyors
- Toothed belt conveyors
- Roller conveyors
- RFID or 2D barcode system
Handling systems & robotics
- SCARA robot
- 5 and 6 axis robots
- Linear axes
- Electrical rotary and linear drives
- Pneumatic, hydraulic and electric handling systems
- Turning stations
- Vertical and horizontal converter
- Gripper (vacuum, Bernoulli, adhesion, …)
- Tensioner
Measure
- Light, pressure, power, distance
- Acceleration, torque, weight
- Current, voltage, resistance, tightness, flow, temperature, pressure, optics, volume
- Vision systems
Process controls
- Inductive sensors
Capacitive sensors
Tactile sensors
Optical sensors
Industrial image processing
Vision sensors
In-circuit testing
Data management, traceability
Current and voltage measurement
Torque testing
Force measurement
Thickness measurement
Particle testing
Length measurement
Final inspection
To mark and labelling
- Laser marking
- Inkjet marking
- Labeling systems
- Needling systems
- Pad printer
- Milling
Packing
- Bag
- Cartons
- Packages
- Pallets
- Trays
- Accumulators
- Boxes
Our business areas
AUTOMOTIVE
AEROSPACE
SEMICONDUCTORS
ELEKTRONICS, SENSORS & OPTICAL SYSTEMS
FOOD, PHARMACEUTICAL & MEDICAL
TEST EQUIQMENT CONSTRUCTION
RECYCLING
SPORTS
SOLAR AND PHOTOVOLTAICS(PV)
Gabriel Tobescu
Your contact
Your partner for
special machines construction
and automation
Do you have an application where you need a bespoke or product-specific solution? We would be happy to analyse your project with you and develop a suitable plan for its implementation. We look forward to hearing from you.
