Winkler and Dünnebier Süßwarenmaschinen relies on retrofitting, exchanging outdated components for new, modern technologies. This is how WDS brings existing systems up to the technical standard of a new system. By converting hydraulics to servo technology or developing individual solutions for replacing discontinued servo components, older machines receive a boost in terms of efficiency, reliability, spare parts availability and service life.
Long-lasting WDS confectionery machines for producing castable and injectable masses from the 1950s are still in operation today and are serviced by WDS. The modernization of older systems through customized retrofits can increase the productivity and efficiency of an existing system and thus be more economical than investing in a new system. The familiar machine concept ensures that the basic system remains functional, user-friendly and process-oriented. Retrofitting can often be done with only minimal downtime.
Process optimization at Continental Candy Industries: replacement of hydraulics with servo technology
There are many reasons for modernizing equipment. In 2011 WDS began replacing the old hydraulic depositors with servo technology. This had become necessary because many parts were no longer available, which meant that the supply of spare parts could no longer be guaranteed. There are also hygienic reasons for choosing a more modern solution, given the hydraulic fluid used. The process engineering benefits include more precise motion sequences and easier operation.
In 2019, WDS carried out extensive retrofitting work for our customer Continental Candy Industries in the Netherlands. The hydraulic components used to drive the depositor were phased out. This meant that the availability of spare parts was no longer guaranteed. CCI decided to modernize the existing 361B mogul plant to make it more reliable and efficient by upgrading the control system. The hydraulic depositors in the 1983 plant were converted to servo drives. A completely new control cabinet and a modern HMI were also installed.
The customer also decided to install new casting containers and pump systems from WDS that meet the current state of the art. As part of the conversion, the existing feeder and stacker were replaced with the latest versions and thus converted. As part of the electrical conversion, all safety switches were converted from 230 volts to 24 volts or replaced and integrated into the new control system.
Retrofit with only four weeks of downtime
From the time the order was placed until the time of installation at the customer's site, about half a year passed. During this time, the conversion parts could already be tested at WDS. This meant that the installation and commissioning could be carried out with a defined schedule within a four-week shutdown.
CCI had already completed some preliminary work before the on-site installation work began. This included checking the cable labeling, opening the cable ducts and dismantling the existing system by removing the casting container and the pump system. The team, consisting of seven WDS and six CCI specialists, then began installing the new components, connecting the new switchgear and modifying the existing systems.
Servo technology enables the plant to continue operating
“The retrofit conversion to servo technology enables us to continue to operate our plant while meeting standards of safety, hygiene and profitability. The new plant control in line with the current standard enables us to produce with an improved OEE. Safety for our staff has improved and the new HMI control system has given us more insight into the performance of our machine”, says John van Dongen, Project Coordinator at CCI.
WDS draws a positive conclusion for retrofitting confectionery machines
Confectionery machines with long-lasting mechanical systems can be extensively modernized even decades after purchase through various retrofitting measures such as technology changes, new cabling or digitization measures. In the best case, systems can be upgraded to the technical standard of a new system. The modernized systems are a real benefit in terms of efficiency, production volume, production quality and sustainability.
