Refurbishment for IML Automation Systems in North America

Give Your Existing IML System a Second Life: Faster, Smarter and More Reliable

Replacing an In-Mold Labeling (IML) automation system is a major investment. Nevertheless, in many cases, the machine frame and mechanical platform are still in excellent condition. The real challenges lie elsewhere: worn components, obsolete electronics, increasing maintenance effort and unplanned downtime.

Our comprehensive modernization program brings existing IML automation systems back up to the current state of the art while significantly extending their service life. Instead of replacing your entire production system, we build it entirely from scratch using new components, state-of-the-art automation technology, and improved diagnostic capabilities

The result is a modern production system with higher availability, lower maintenance costs and performance comparable to a new machine, at a fraction of the investment.

Refurbishment Services Across North America

Our experienced service team performs complete refurbishments for IML automation systems throughout the United States, Canada and Mexico.

From the initial system assessment through installation and recommissioning, we support customers with a structured modernization process that minimizes production interruption while maximizing long-term machine performance.

Whether your system requires mechanical rebuilding, electrical modernization or a complete automation upgrade we will help you extend the value of your existing investment.

When is the Refurbishment the Right Choice?

After years of continuous production, every automation system reaches a point where maintenance becomes increasingly expensive. Millions of operating cycles lead to wear on mechanical components, spare parts become difficult to source, and troubleshooting consumes valuable production time.

Typical signs that your system is ready for refurbishment include:

Increasing machine downtime
Obsolete electrical components
Rising maintenance costs
Difficult troubleshooting
Longer repair times
Higher risk of unexpected production failures

Waiting until a major failure occurs usually results in significantly higher costs than proactively modernizing the system.

More Uptime Means More Production

Every hour of unexpected downtime costs money. Our refurbishment program is designed around one primary objective: maximizing Overall Equipment Effectiveness (OEE).

Benefits include:

Increased machine availability
Faster troubleshooting
Reduced maintenance effort
Lower spare parts costs
Higher process reliability
Longer service life
Improved operator usability
Reduced production interruptions

Instead of constantly reacting to failures, your maintenance team gains a reliable production asset that supports long-term manufacturing stability.

Complete Mechanical and Electrical Rebuild

Our refurbishment process goes far beyond replacing individual wear parts. Each machine is completely dismantled before every critical component is inspected, replaced or upgraded. The machine frame is professionally cleaned, repainted and rebuilt with new mechanical and electrical assemblies. Replaceable components are:

Belt systems and pulleys
Pneumatic cylinders, hoses and valve technology
Servo motor, sensor and power cabling
EtherCAT communication wiring
Vacuum systems
Conveyor components
Sensors
Beckhoff I/O modules and new Beckhoff PLC running TwinCat 3
Shock absorbers
Vacuum cups and buffers
Fasteners and hardware

The result is a machine that performs like new while utilizing the proven mechanical foundation of your existing equipment.

Modern Automation Technology for Maximum Reliability

In addition to rebuilding the mechanical system, we upgrade the complete control architecture using current industrial automation technology. This includes:

New Beckhoff PLC with TwinCAT 3
A modern PLC platform delivers faster processing, improved diagnostics and simplified future software modifications.

Latest Beckhoff Servo Drives and Servo Motors
Modern servo technology increases reliability while making future replacements significantly easier and more cost-effective.

Heavy-Duty Operator Interface
The newest touchscreen generation provides operators and maintenance technicians with extensive diagnostic information directly on the machine, including EtherCAT diagnostics, maintenance reminders and system status monitoring.

New SMC Valve Technology
Modern valve islands simplify maintenance while improving pneumatic performance and reducing troubleshooting time.

Updated Machine Safety
Emergency stop circuits, safety switches and acknowledgement systems are upgraded to current safety standards while simplifying wiring and improving maintenance.

Sustainable Manufacturing Without Replacing the Entire Machine

Refurbishment is not only economically attractive, but also a sustainable alternative to purchasing a completely new production system. By reusing the machine structure while replacing critical wear and automation components, companies significantly reduce material consumption, transportation effort and environmental impact. The result is a modern production system with substantially lower investment costs and a significantly smaller carbon footprint.

Ready to Modernize Your IML System?

Don’t wait until worn components cause costly production downtime. Contact our refurbishment specialists today to discuss your existing automation system and discover how a complete refurbishment can increase productivity while reducing maintenance costs.

Request your individual refurbishment assessment today.