Success Story – Retrofit einer Krempel-Anlage

Success Story

Retro­fit of a card­ing machine

Complete technical plant overhaul and optimization of an existing plant.


The goal was the com­plete mod­ern­iza­tion of an exist­ing plant pro­duc­ing woven felts for use in the paper indus­try. The machine con­sist­ing of shred­der, box feed­er, coarse and fine card, and a cross lap­per came from the 80s. The life­time of all com­po­nents was exceed­ed and the sys­tem had to be brought up to the state of the art.

Mechan­i­cal modernization

The machine was dis­as­sem­bled into all indi­vid­ual parts and all wear­ing parts of the sys­tem were replaced. Pre­vi­ous­ly chain-linked move­ments were decou­pled by using sin­gle-ser­vo dri­ves. The numer­ous new engines and gear­box­es had to be adapt­ed to the exist­ing plant. All trans­mis­sions were rebuilt on tim­ing belts.

Elec­tri­cal modernization

It was nec­es­sary to replace the com­plete elec­tri­cal machine instal­la­tion, includ­ing the con­trol cab­i­net and oper­at­ing lev­el. All safe­ty func­tions were imple­ment­ed by using a safe­ty con­trol and cor­re­spond­ing dri­ve controllers.

Process opti­miza­tion and visualization

By means of a visu­al­iza­tion spe­cial­ly tai­lored to the plant, a user-con­trolled con­trol sys­tem as well as an opti­mal process mon­i­tor­ing of all plant con­di­tions could be real­ized. By sep­a­rat­ing the dri­ve tech­nol­o­gy into 30 syn­chro­nous­ly oper­at­ed ser­vo dri­ves, the flex­i­bil­i­ty and dynam­ics of the sys­tem has been increased.


The exist­ing oper­at­ing instruc­tions of the sys­tem have been added. New CAD draw­ings of the plant were cre­at­ed. It was nec­es­sary to pre­pare a risk assess­ment in accor­dance with the Machin­ery Directive.


The numer­ous mea­sures result­ing from the assess­ment and addi­tion­al pro­tec­tion devices had to be imple­ment­ed mechan­i­cal­ly and elec­tri­cal­ly. This increased the safe­ty of the sys­tem many times over.

Contact Person
QA Geschäftsführer Christian Franssen
Christian Franssen, ppa.
Electrical Engineer
Specializations: Electrical Engineering, machine safety regulations, project management
Our philosophy

Only if our systems are integrated at the customer completely they develop their entire performance potential. Therefore it is important for us that our customers are integrated in the process from the very first day of the project carry out. Communication is about it the most important connecting part between us and our customers.

Customer targets
  • Maximum production efficiency and quality
  • Stable industrial processes
  • Well trained personal
  • Low service costs
  • Most favorable conditions