Service Retrofit

Before and after – modernisation instead of buying new

Application report Retrofit Flexmaster for BOLL & KIRCH

This Flexmaster 400 was sold to the current customer in 2002 as a CO2 laser version: Boll & Kirch Filterbau GmbH uses it to manufacture filter tubes. At that time, the product range of the standard machine was expanded to include a special welding arm and specially equipped for welding perforated metal sheets. In addition, a TIG welding source was integrated into the machine in 2004 as an alternative welding process to laser welding.

In 2012, BOLL & KIRCH purchased another Flexmaster with a CO2 laser. From then on, the older machine was only operated with the TIG welding source – until 2024. By then, the technology of the 22-year-old machine had become outdated. In consultation with us, it was decided to carry out a retrofit overhaul of the entire machine, including the TIG welding source.

‘We are very satisfied with the two Flexmasters in our production and wanted to keep the old system. It just needed to be brought up to date in terms of control and welding technology,’ says Felix Nink, Electronic Engineer Maintenance at BOLL & KIRCH.

Details on the retrofit of the Flexmaster 400 from BOLL & KIRCH

The machine was gutted at our plant in Müllheim and refitted with the latest Flexmaster systems:

• The latest Siemens drive technology

• A current valve terminal from FESTO

• The latest Euchner safety door switches

• New touch panel from Siemens

In addition, we have added further individual features in response to customer requests:

• curtent TIG laser source

• current TIG torch

• automatic security window

• Interface with own PLC for operational data acquisition

In short:
All cables, sensors, air and gas lines, cylinders, switches, motors, panels, welding sources and the entire control cabinet were replaced. Finally, everything was readjusted, aligned and inspected as part of the annual maintenance.

BOLL & KIRCH is delighted with the new old Flexmaster:
‘The system spent four weeks at Weil Technology in the summer and was then successfully recommissioned at our company in Kerpen by one of the WT technicians within a short period of time. Since then, it has been running reliably in our production again as usual.’

Retrofit: Bring your machine up to date

Many of our customers continue to reliably use machines they purchased years ago. However, requirements and technologies are constantly evolving. That's exactly why we offer our retrofit service: We bring your existing system up to the current optimum standard. This saves costs compared to purchasing a new system and ensures greater efficiency and safety

Our retrofit services:

• Upgrade to energy efficient laser technology

• Conversion to the latest control technology

• Safety upgrades

• Increase the energy efficiency of the entire system

• Ensure the supply of spare parts with the use of new components

Personal consultation on retrofitting and manufacturing requirements

We would be happy to advise you on your retrofit and manufacturing requirements and show you how retrofitting can make your machine efficient and future-proof.