In practice

In practice

Ground-breaking molecular diagnostic tests

The recent pandemic taught us that rapid and reliable tests at low cost are key to future prevention and control of transmissible diseases. High throughput testing for many upper respiratory tract pathogens is now possible, using automation technology.

In practice

When "Play" becomes art

The striking music played by eight cellists fills the space. Suddenly the space is illuminated by light effects, while eight arms rise up slowly behind the musicians and close up around them like a cocoon. This special design – called COCON – was created by artist Nick Verstand and realised in collaboration with fellow artists Daniël de Bruin (mechanics) and Wes Broersen (software). Festo implemented the electric drive and motion technology that was required to sync the movements every 4 ms in real time with the music and the surroundings.

In practice

Navigating the Laboratory Automation Landscape

In the fast-paced world of lab operations, efficiency is paramount. Laboratories are critical in scientific research, quality control, and innovation across various industries. However, despite technological advancements, labs often encounter many challenges that hinder their productivity and effectiveness. These obstacles can impede progress and compromise outcomes from resource constraints to regulatory compliance.

In practice

QM Systems develop automated mass testing system

Industrial automation specialist Festo and systems integrator QM systems have collaborated on the evolution of a new automated laboratory system that fills, caps and labels test vials at speeds of up to 3000 vials per hour.

In practice

Innovation partnership between Festo and Würth

The innovation partnership between Festo and Würth has already lasted two years, and the first phase of the partnership is now coming to an end – with success: the prototype works. Würth wants to comprehensively test Festo's tailor-made AI software solution at the Reinhold Würth Innovation Centre Curio, discuss it with employees and, if everything proves successful, implement it in its logistics centres worldwide.

In practice

Save time configuring your process valve unit

There are endless ways to get your media from point A to point B. But there is only one best way. We at Festo want you to find this way. The best possible solutions for your process ball valves, butterfly valves and top works . We offer you everything from a single source – from field level to the control level.

In practice

Fully automatic packaging line for steel fibres

'When a German manufacturer asked if we could build two identical packaging lines to pack steel fibres fully automatically into boxes and stack them on pallets, we enthusiastically embraced the challenge,' says Simon Rijke, CEO of The Hague-based Weighpack. But soon, their engineers realised that this required additional know-how, especially in the field of linear drive technology. Festo was brought into the project to collaborate on the final solution.

In practice

Cellro helps customers transition to Industry 4.0

In its ambition to bring its automation solutions for CNC machines up to the level of Industry 4.0 and beyond, Cellro took a close look at the hardware and software of its systems. This resulted in a major transition in which the Festo Motion Terminal played a major part.

In practice

Quick automatic sorting in agriculture

Manually removing damaged or diseased potatoes from the harvest is a labour-intensive and complex job. Martijn, Lars and Stefan Flikweert of Flikweert Vision Technologies decided to develop a potato sorting machine that automatically sorts potatoes based on vision and artificial intelligence. To achieve the required speed and flexibility, Festo supported in choosing the right cylinders, controls and bus system. The end result is a machine that can process up to ten tons of potatoes per hour.

In practice

Automating Easter egg mix

In a new installation for mixing chocolate Easter eggs, Mondelez in Herentals, Belgium has resolutely chosen electric drives. The main reasons for this are lower energy consumption, higher safety and more flexibility in controlling speeds and positions. An ingenious system of conveyors ensures that everyone finds a nice mix of flavours in their pack of chocolate eggs at Easter.

In practice

An automatic warehouse for chips in no time at all

What do you do when you need to build a complete automatic storage system for high-end products within three months? The automation and product development company EPHI called Festo to work with them. The Eindhoven-based full-service supplier managed to help its Asian customer at lightning speed with an automated storage and retrieval system for semiconductors.

In practice

Authentic organ sound through modern technology

For the restoration of the 18th-century mechanical organ in the village church of Woubrugge, organ builder Elbertse & Van Vulpen took a special decision: instead of using an air pump to generate wind, an ingenious solution was devised that authentically creates wind through the original bellows. In a collaboration with Festo and ERIKS, the idea was translated into a technical solution in which a servo-driven spindle guide, sensors and controls in a custom-built control box take over the work of the ‘calcants’, the organ pedals.

In practice

Festo pneumatics expertise helps Cerulean

Soaring energy prices and the need to continuously drive down costs are key considerations for manufacturers. So, when packaging machinery specialist Cerulean decided to redesign its highly successful FPS-1 tube packer, high energy efficiency and reduced total cost of ownership (TCO) became key design requirements.

In practice

Selecting the optimal linear motion technology

Linear motion on machines traditionally uses pneumatic or electric drives, but there are more options available today than designers may realise. Josh Roberts, Product Manager at Festo GB, explains how to make the best selection for your application.

In practice

Soft fruit quality control sped up

Karsten Europe handles the distribution of grapes from Africa and has recently started fully automatically checking the quality of imported grapes via an AI aided vision system from the company Gearbox. Besides advanced hardware and software, at the heart of this machine are electric drives from Festo's Simplified Motion Series, which are used to eject failed products in a controlled manner. Gearbox opted for the simple electric automation solution because it saved having compressed air as a secondary energy source, and because electric drives provided the repeatability they required.

In practice

Robotic automation is racing ahead

It is an exciting time in engineering automation. Over the past decade, the pace of innovation has accelerated automation and robotics to meet demands from the sector. Global sales volume of industrial robots has tripled[1] and the industrial robotics market is projected to reach USD 30.8 billion by 2027, from 17.68 billion by 2022, growing at a CAGR of 14.3% during the forecast period[2] .

In practice

Five ways to optimise pneumatic systems

Andy Macpherson, Industry Manager for Food & Beverage at Festo GB, offers advice to help system designers adhere to food safety guidelines while improving machine utilisation and performance.

In practice

Steps for creating sustainable automation business

Steve Sands of Festo looks at how the experiences the company has gained internally toward its environmental and sustainability goals are translated into practical help and support for their customers.

In practice

AI in machine control is a positive evolution

It’s a challenging time for Artificial Intelligence (AI) as the wider public have dramatically become aware and been able to access the technology. Broad public consciousness has mushroomed as tools like ChatGPT became mainstream in just a few months. However, this hasn’t been all good news for the technology as there have been many more negative press stories about its potential misuse than its power for good. The break-out of AI has stirred negative associations from fiction and gaming about rogue machines and computers wreaking havoc. It is important the engineering community is aware and communicates the benefits of the technology, differentiating the industrial applications where we can massively improve productivity, reduce energy consumption, and become more competitive.

In practice

Why should I automate my liquid handling process?

In today's rapidly evolving scientific landscape, laboratories are under increasing pressure to deliver accurate and precise results efficiently. The key to achieving this lies in adopting automated liquid handling processes. Here's why:

In practice

Festo automation technology aids restoration

Rapid leaps in innovation characterise the development of additive manufacturing processes. Rotterdam-based company Concr3de has been working on a 3D printer for stone for more than five years, developing an inkjet technique to participate in the reconstruction of Notre-Dame Cathedral in Paris. They achieved this aim using automation technology from Festo.

In practice

Scaleable remote I/O and valve terminals

"In-basket and out-basket, or 'basket loader/unloader'?" laughs Van den Akker. Whatever their latest construction is called - it is Apollo Engineering's latest automation project. The installation collects filled cans and transfers them to an autoclave for sterilisation, collecting them again on the return.

In practice

Complete servo drive portfolio

Reducing complexity and securing reliable supply is critical to success when it comes to machine building. Nigel Dawson, Head of Business Development for Electric Automation at Festo explains how Festo is assisting the industry in connecting devices seamlessly and reducing the complexity of supply and control.

In practice

Dry where it needs to be, standard where it can be

TNO approached Festo with the request to upgrade its existing compressed air system. More compressed air was needed, and also of better quality. Based on a pre-audit, a working group with Royal HaskoningDHV was put together and a proposal was made for two separate systems, each providing its own quality of compressed air. With the additional possibility of linking the systems in case of calamities, TNO has raised the availability, capacity, quality and efficiency of its compressed air supply to a higher level.

In practice

Robotic automation, development at pace!

Whether it is the alignment of key technological trends or the societal upheavals caused by global pandemics and rising climatic temperatures, the impacts are being felt in our factories and our shops. We have talked for many years in the engineering automation sector about the accelerating pace of innovation and whether this is real or solely our viewpoint perception. I believe there are many exciting changes afoot. Talking with our customers at shows and events I hear about the change drivers they are experiencing and how these manifest in their businesses: for example, as labour shortages in fields and factories, rising energy costs or the need for higher flexibility and productivity. For Festo and other automation suppliers, the result is increasing opportunities for automation and robotics.

In practice

Making connectivity easier

Innovation creates opportunities, and this article explores how necessity led Festo to positive outcomes for machine builders and end-users as we adjusted to the global semi-conductor chip material shortages. In a very short time during the crisis Festo developed and launched a complete, new multi-protocol range of extra-low and standard servo drives that seamlessly connect to the leading networks, ensuring seamless connectivity combined with a reduction in complexity. This enables control panels to remain the same despite fitting into different architectures and at the same time offering the latest electronics, multiprotocol functionality and improved performance, all with a much-reduced inventory.

In practice

Torus and Festo design total handling solution

Torus Technology Group has partnered with Festo to create a purpose-designed integrated handling solution for its new TQ-Lab modular plastics packaging testing station.

In practice

Sustainability using controlled pneumatics

Rising energy prices are pushing up the cost of process gases. This not only applies to compressed air, but also to inert gases, oxygen, and exotic gases. These gases are used for many everyday applications, such as food packaging and tyre inflation, as well as highly precise and technical applications in semiconductor production and scientific research. Rising costs have a knock-on effects throughout the supply chain, because production of even the most basic foods, medicines and industrial components is dependent upon the cost of the gases they consume. For manufacturers to remain competitive, the case strengthens for carefully re-evaluating the technology used to control flow and pressures in order to use process gases more efficiently and sustainably.

In practice

Improving predictive maintenance using AI

The world is in a state of accelerating digital change. In an industrial context machine learning, advanced analytics and artificial intelligence (AI) are tools with enormous potential to deliver improved predictive maintenance strategies, but how these tools are applied is critical to success.

In practice

How does an air preparation unit work?

In this journal we explained that an air supply in a pneumatic system is necessary to maintain the compressed air quality and to control the machine centrally. This is extends the life of the components and optimises the operation of the machine in terms of reliability, availability, efficiency (energy consumption), safety and accuracy. Find out what components that are required to achieve this.

In practice

What is an air preparation unit?

Pneumatic systems work on compressed air. A medium that transmits power to, for example, cylinders, grippers and valves, which can then perform their task. For example, gripping a product, creating a linear displacement or developing a holding force. The quality of the compressed air largely determines the performance of the pneumatic system. Among other things, in terms of efficiency, effectiveness, safety, reliability, accuracy and speed. It is therefore important for practically every industrial pneumatic system that the compressed air used is of the correct quality. In this blog we will explain the role that the air preparation unit plays.

In practice

Festo Technology Engineering Center (TEC) Boston

In order to contain rising costs in the healthcare sector, there is a worldwide need for automated systems that support medical research. Fluid handling plays an important role in this. Especially for this purpose, Festo started the Technology Engineering Center in Boston in 2018. Three teams with a total of 20 engineers work daily on both customer-specific systems and catalogue products for fluid handling. Speed, accuracy and modularity are the key words with which system builders can optimise the time-to-market of their equipment.

In practice

The reasons for an individual learning portal

Digitalisation is permeating all areas of life, and vocational training is also feeling the effects. With LX, Festo has developed a digital learning portal that responds to developments that are permanent.

In practice

Cylinder cushioning: the three most common methods

Pneumatic cylinders are set in motion by means of air pressure, they accelerate, but at some point they also have to slow down and come to a stop. Depending on the application, different types of damping are used for this: a method or element to completely absorb the kinetic energy that has built up, causing the cylinder to stop in a controlled and safe manner. In this first part of a series of articles on pneumatic cylinders, we explain the three most common types of cushioning and their properties. What are the advantages, the limitations and when do you actually use mechanical, pneumatic or hydraulic end cushioning?

In practice

Retrofitting with VTEM increases productivity

Serious steps in pneumatics can be made by smart retrofitting: removing old valves and replacing them with the VTEM digital motion terminal reduces hardware and increases functionality, speed and flexibility. Controlling and setting are done remotely with a simple app. But what about the older production machines? After sometimes decades, they still run their production steadily and reliably. However, in the light of current times, they no longer meet the requirements and wishes with regard to energy efficiency and speed. Remote monitoring and control also become difficult. Serious steps in the field of pneumatics can be made by smart retrofitting: removing old valves and replacing them with the digital motion terminal VTEM reducing hardware and increasing functionality, speed and flexibility. Controlling and setting are done remotely with a simple app.

In practice

Choose between 4 types of compressed air hoses

Compressed air hoses are the figurative lifeblood of a pneumatic system. These cores are essential for transmitting the compressed air generated by the compressor into machine movements. Because of this vital function within the compressed air system, it is very important to choose the right compressed air hose. A correct selection not only prevents unnecessary leaks (and therefore costs), but also ensures a higher reliability of the machine (fleet). In this blog we describe the characteristics of our range of hoses, which materials we use, what the application areas are and how to make the right selection.

In practice

Simple digitisation with CPX-AP-I

Making machines fit for the future means digitising them. With so many different communication protocols and control options, this is not always easy. How do you ensure that all components can (continue to) communicate with each other and the higher control system without having to redesign an entire topology? Festo offers a solution with the CPX-AP-I; a decentralised I/O platform.

In practice

Choosing software for machine maintenance.

Maintenance based on paper schedules or Excel lists is labour intensive and prone to error. Today's maintenance mechanics use handy apps and software tools with which maintenance can be carried out efficiently and at exactly the right time. Various tools provide online access to all necessary machine-related information and maintenance planning. But what do you actually need to consider when selecting such a tool? In this blog, we explain the points for consideration and make suggestions.

In practice

Pneumatic cylinders and extreme temperatures

Just like dirt and dust, temperature is a challenge for every machine builder. Will the machine or application be located in an extremely cold environment or in a very warm environment. Or does the temperature vary enormously? And how does a pneumatic cylinder react to this? In this blog we will explain what the problems and challenges can be, what possibilities Festo offers and which product ultimately can be chosen best for a particular application and temperature range.

In practice

Electro-pneumatic diagrams in an instant

Drawing up the electro-pneumatic diagram of a valve island does take some time; from a few hours (for the simplest) to several days (for the most complex). This is a job that machine builders are finding it increasingly difficult to ignore. Schedules are crucial for those who want to take the step towards predictive maintenance. But it can be done faster. Much faster. With Schematic Solutions they get completely error-free, norm-compliant EPLAN documentation in just a few minutes. Ready to use for about £80.

In practice

What is a pneumatic valve?

Pneumatic systems work on the basis of air pressure. This means that compressed air is the medium that transfers energy to different users in the system. For example, to a cylinder to achieve a movement or to a gripper to achieve both a movement and a gripping force.

In practice

Everything you need to know about valves!

Pneumatic valves are distinguished by the number of connections and the number of switching positions. Mono- or bi-stable / NO or NC.

In practice

Cylinder sensors for extreme environments

For standard industrial applications, standard cylinder sensors are sufficient. Extreme, challenging environments often demand more from a sensor. And that means: special versions and special properties.

In practice

Cylinder sensors for limited installation space

Cylinder sensors are mainly used for determining the position of a piston rod or gripper. The measured value is fed back to the control system and used here for sequence control, monitoring or surveillance.

In practice

Tips for mounting and connecting cylinder sensors

Cylinders are often equipped with various mounting and connection options for cylinder sensors. This blog provides tips & tricks on how to make smart use of these possibilities. It saves time and space and is a prerequisite for the correct and reliable functioning of the sensor. In addition, there are tips and tricks for cylinders that do not have smart mounting and connection possibilities.

In practice

Create circuit diagrams with FluidDraw

There are many good reasons to provide schematics for machines and pneumatic systems, but drawing them is often seen as a difficult and time-consuming task.

In practice

What is a flow control valve?

Flow control valves are used in pneumatic systems to regulate the flow rate of compressed air. By controlling the flow rate, the speed of the pneumatic cylinder can also be regulated directly. In addition, a good throttling valve contributes to reducing wear due to a lower kinetic load. Moreover, the control valves also support a more steady and thus reliable movement. The latter has to do with the fact that if the speed is unthrottled, the velocity can fluctuate. This in turn can lead to a stick/slip effect and thus to a faltering motion.

In practice

"Core range goes together just like toy bricks."

If you know what you are good at, you also know where you can use reinforcement. Lucas van Leeuwen gathers people and knowledge around him to move his company and projects forward. We asked him why he likes to collaborate with Festo.

In practice

L'Oréal and Festo - a unique strategic vision

L'Oréal, based in Libramont, Belgium since 1975, specialises in the production and packaging of hair colouring and hair care kits for the European consumer market. This production site, a pioneer in sustainable development, has just warmly welcomed the MSE6-E2M energy efficiency module with preferred partner Festo.

In practice

PCE help Frugalpac make sustainable wine bottles

A collaboration between Festo and PCE Automation has helped recyclable packaging experts Frugalpac™ Limited to achieve the high throughputs and precision assembly necessary to meet increased demand for its innovative paperboard Frugal Bottle.

In practice

The fast route to a safe insulin pen

Diabetes is on the rise worldwide with around ten million people developing the disease every year. Demand for insulin pens allowing patients to self-medicate is similarly high. Syntegon’s Danish subsidiary has developed an automated system to assemble the pens using the Festo automation platform.

In practice

Grolsch bottling plant upgrade goes with a swing

New servo technology from Festo is helping Grolsch to put the iconic swing tops on its bottles of lager. The ‘swing-top transfer unit’ was custom-designed by Festo in conjunction with system integrator MCA Linear Motion Robotics and is installed at the Grolsch Enschede plant in The Netherlands.

In practice

Energy audit achieves 20% savings for Unilever

How simple changes save thousands on compressed air at Unilever Port Sunlight

In practice

Cerulean collaborates with Festo

Cerulean, a manufacturer of tube packing solutions, has collaborated with industrial automation specialist Festo to simplify the design of its popular FPS-1 tube packer to deliver an improved, more energy efficient, and future-proof packing solution.

In practice

PCE Automation uses Festo Technology

Festo automation technology is being used to help STANLEY® Tools in the UK to meet continued demand for its renowned safety knives, while continuing to maintain the highest standards of safety and quality.

In practice

Efficient use of blood plasma

Blood plasma is an indispensable resource in the production of life-saving medicines. It is in high demand on global markets. To make more efficient use of this valuable commodity, Biotest AG developed a new large-scale plant for plasma fractionation, with which it is possible to obtain five instead of the previous three products from a litre of blood plasma. Standardised components from Festo simplify installation and maintenance.

In practice

Fibre balls in the fight against micropollutants

Each year, 8,000 tonnes of pharmaceutical products and 10 tonnes of microplastics alone end up in Germany’s largest river, the Rhine. Conventional wastewater treatment plants will always struggle to deal with such large quantities of micropollutants. That is why the town of Barntrup in the German state of North Rhine-Westphalia added a purification stage for micropollutants to its wastewater treatment plant – a world first using Fuzzy Filters® from Bosman and automated with pneumatics from Festo.

In practice

Producing twenty times more

A twenty-fold increase in production was the goal of the Croatian car cosmetics company Alfa Car. To achieve this, the entire production cycle, housed in a new production plant, was automated. Festo supplied a complete solution for more than 200 process valves – including project management.

In practice

The dock that “thinks” for itself

The world of bulk material handling seems straightforward at first glance: moving, filling, delivering. However, the art of dealing with a variety of different materials is in the details, such as the docking and undocking of containers at weighing stations. In the process, cross-contamination can occur and dust can be released. The AZO CleanDock prevents this problem. Its latest generation can do even more: it “thinks” for itself. Directly attached to the dock, the integrated controller CEC of the modular electrical terminal CPX from Festo ensures additional process reliability and shortened commissioning times.

In practice

40,000 DNA extractions daily

It's great when things run quickly: 20 minutes per extraction process and a new plate every 2.5 minutes – the Dutch company Synchron Lab Automation, in cooperation with Festo, has developed a small automated factory for DNA extraction. As a result, customers in the seed industry can collect DNA from up to 40,000 samples per day.

In practice

A Swabian recipe for success

Soft pretzels are one of the most popular breakfast treats in southern Germany. It takes skill, practice and time to achieve the perfect symmetrically twisted shape with a fat belly and thin arms. Or simply a clever automation solution.

In practice

Improved quality of life

Around 600 million people worldwide are afflicted with chronic obstructive pulmonary disease (COPD). Mobile oxygen system devices improve the mental and physical ability of patients as well as their quality of life. Japanese company Musashi Medical Laboratory supplies easy-to-operate regulators in smartphone format for these oxygen system devices, thus significantly improving comfort and handling for patients. Compact piezo valves from Festo provide for quiet oxygen supply.

In practice

Fully Automated DNA Extraction

In plant breeding, countless DNA samples are examined in the laboratory every day. Breeders face the technical challenge of testing DNA quickly and accurately. An automated machining jig supports the automated laboratory in the preparation of samples for analysis.

In practice

High-tech wood cutting

“With our new automated saw, we achieve a speed of 150 metres per minute. This makes it the fastest band saw line in the world”, explains Johan Fredriksson from Swedish timber supplier Norra Timber. The modular line was supplied by the Swedish subsidiary of the American system builder USNR. It includes the flexible function terminals CPX/VTSA in key places for actuating the pneumatic and hydraulic systems.

In practice

Precision in eye surgery

Nowadays, cataract surgery is a routine procedure. This is in part due to the pioneering developments in medical technology from companies such as BYTEC, which produced the “QUBE” to support eye surgeons deliver precise and faultless treatment. Piezo, proportional and fast-switching valves allow the necessary rapid incisions to be made.

In practice

Safe cleaning for the pharmaceutical industry

Wherever work involves using active ingredients, cleanliness is of the highest priority; production equipment has to be thoroughly cleaned every time it is used. And of course this makes the system prone to wear. Unless you use corrosion-resistant, stainless steel components from Festo. They are more resistant. For example in cleaning systems from ROTAN for the pharmaceutical industry.

In practice

Infusion solutions

B. Braun Melsungen had a great idea and implemented it throughout the plant. Production for infusion solutions was to be largely standardised. B. Braun hoped this would lead to increased productivity, improved process stability and, at the same time, reduced operating costs. And it worked. With support from Festo.

In practice

Production in the fast lane

With a 95% degree of automation, the Scania body shop in Oskarshamn, Sweden is one of the most modern vehicle manufacturing plants in the world. At the same time, the plant supports extensive customization. By the time they reach the end of the assembly line, virtually no two truck cabs are the same. So is this the Industrial Internet of Things in action? Automation products from Festo have certainly provided a solid basis.

In practice

LED it be

Austrian plant engineering firm Vescon developed a solution for producing modern LED headlights for the Slovakian plant of well-known Tier 1 supplier. The focus was on efficient handling systems, the correct processing of time-critical production steps and end-to-end traceability. Specialists from Festo's Technical and Application Center, who were taking care of the turnkey handling systems, made up part of the team.

In practice

The art of making kitchens

It was not by chance that nobilia became Europe’s largest kitchen manufacturer. So, what is its recipe for success? Efficient kitchen unit production on highly automated assembly systems, many of which are supplied by Hüttenhölscher and use Festo automation products – equipped with IO-Link® – to improve flexibility and availability.

In practice

Speed in battery testing

The trend for electric vehicles is clear. However, their success depends on high-performance and cost-effective batteries. In the UK, the pilot project AMPLiFII at WMG is laying the foundations of a new generation of traction batteries. The project includes innovative automation technology from Horizon Instruments with a Festo pick and place solution.

In practice

Carefully packaged

The servo-controlled horizontal cartoner HK-S from ECONO-PAK gently and efficiently places scratch-sensitive tubes of shoe polish into cardboard boxes. The freely configurable and flexible Multi-Carrier-System (MCS) from Festo perfectly synchronizes the conveyors for the product and the cardboard box and ensures reliable packaging with high throughput.

In practice

Exactly the right dose

Coffee, sugar, pharmaceuticals—nowadays, virtually everything is packed in small, low-cost sachets. The new, flexible flat pouch machine Sigpack VPF from Bosch Packaging Technology ensures correct packaging and a precise mixing ratio. The world's first freely scalable sachet machine uses the new flexibility provided by the digital pneumatics of the Festo Motion Terminal.

In practice

Standing strong

The Doypack® brand has been synonymous with practical stand-up pouches for over 50 years. The patent is held by French company Thimonnier, which is increasingly moving towards mechatronics and ultimately Industry 4.0 for the development of its filling and packaging machines. Pneumatic and electric automation technology from Festo provides a solid foundation for this development.

In practice

Fresh water for Bursa

The Turkish megacity of Bursa has clean drinking water. There, Festo has completely modernized the Dobruca water treatment plant, from the operating and control level right up to the process valves in the field. It was possible to create an automation system from a single source, thanks to the perfectly matched components from Festo. This also included the supply and installation of a SCADA system, the training of the local staff and on-the-job training from a Festo specialist, who worked full-time there for a year.

In practice

Pneumatics at the water works pays off

Maintenance-free, energy-efficient, safe and extremely strong, in spite of its small size, these are the convincing arguments in favor of pneumatics. It's for a good reason that the water supply company, Landeswasserversorgung Baden-Württemberg, turned to this technology for the construction of a new ground water filtration system. Today, pneumatic automation technology from Festo is at work in the multi-media and activated carbon filtering basins in Langenau.

In practice

Tried and tested solenoid valve technology

The products of the Bayer’s Division Crop Science secure and boost crop yields in more than 120 countries. The new multi-purpose facility built by the company had to meet extremely strict demands on safety and reliability. Inspection cycles had to be significantly reduced, and downtime caused by repairs was to be entirely eliminated in the future. To achieve this, Bayer relied on valve technology from Festo. The facility has now been running smoothly for such a long time that the German Technical Control Board (TÜV) has issued Festo with a certificate for unlimited use of its valves.

In practice

Breaking ranks

Many users of mill-turn centres from Stama are reporting time savings of up to 70% and unit cost reductions of 50%. This is all thanks to the high flexibility of the machines and their virtually negligible setup times. The integrated automation solution from Festo for loading and unloading the workpieces as well as the tool changer in the additional magazine contribute to this success.

In practice

With fluid processes to a sparkling future

Tradition has a name: Kessler. Since 1826, the oldest sparkling wines producer in Germany has been placing its faith in high-quality champagne and other wines – and intends to continue growing in the future with traditional methods and ultramodern production systems. Experts from Festo Training and Consulting are helping to make the new processes as smooth as possible.

In practice

On the valves roller coaster

Every year, more than half a million visitors flock to Familypark, Austria’s largest amusement park. And pneumatics and compressed air provide just as much movement in the park’s numerous attractions. However, to ensure that nothing grinds to a halt and that safety is maintained at all times, the technicians at Familypark completed a two-day seminar held by Festo Training and Consulting – including of course some entertainment.

In practice

Flexible, yet standardised

Just as PCBs have successfully managed to pack an increasing amount of power into a smaller space, developers of plug connectors are working to accommodate more power and a higher contact density into smaller, lighter plug connectors. The family owned British manufacturer Harwin PLC relies on Festo automation to safeguard the quality and flexibility of its production using equipment such as the servo press kit YJKP and the compact handling system YXMx.

In practice

Fresh wind through old pipes

Whether majestic or modest, delicate or complex, whether in a classical church setting or in modern rock music, the organ is the queen of musical instruments. The variety of its sounds remains unequalled. Whilst on modern organs the sound is generated electronically, air still sets the tone on classic instruments. Instead of relying on human muscle power, however, the arduous work of generating wind is now carried out by machines.

In practice

Fully committed to the role

Greater efficiency saves time and money in manufacturing transformers. Special machine builder Straus knows this only too well. The spacers that used to be delivered in strips – resulting in high logistics costs and a lot of waste – now come on a roll. Straus developed and built the necessary machinery to do this. The standardised control cabinet SST from Festo made the job a lot less stressful.

In practice

Picking, packing, and palletizing

“Our design-to-order concept sets us apart from the majority of packaging machine manufacturers,” says Michael Ruf, deputy general manager of Transnova Ruf. In addition to cutting-edge robotic and control technology, the company is using pneumatic automation technology from Festo, and especially proportional technology on valve manifolds.

In practice

100 metres below ground

At CERN, the world’s largest particle physics laboratory, thousands of scientists are working hard to figure out the unsolved mysteries of physics. Their valuable scientific research is supported by the intelligent and flexible application of automation technology. The Festo valve terminal VTSA controls the analysis processes of the air in the experimentation cavern of the Compact Muon Solenoid detector (CMS).

In practice

A stitch in time

Buttonholes are not only functional but also have a visual aspect. However, in textile manufacturing there is generally very little time to produce them. The new automatic eyelet buttonholer 581 from Dürkopp Adler delivers the necessary speed. Thanks to the compact Festo solenoid valves VUVG, it takes just under four seconds to create a buttonhole.

In practice

Clean solutions

Laboratories in the chemical, petrochemical, pharmaceutical and food technology industries are increasingly relying on automation for sample preparation. The Modular Sample Processor, a development from the global laboratory equipment manufacturer Anton Paar, is one such solution – and uses electric axes and control systems from Festo.

In practice

From the display to the mind

The new generation of learning has arrived. The virtual and real learning worlds are increasingly growing closer. This is unlocking interesting possibilities that combine new insights, good memories, and lots of fun. An exciting project at an Austrian school – created by young people for kids – is showing how next-generation learning might work in actual practice.

In practice

Highly precise dispensing of casting resin

From car parking sensors through to smartphones and electric toothbrushes, sensitive electronic components need protection against undesirable substances. This is where special casting resins come in. The “mini-dis” desktop machine from bdtronic allows high-precision dispensing processes in a very small space – thanks, among other things, to the compact handling system YXMx from Festo.

In practice

The skin factory

Our skin – not only the biggest organ of the human body, but also an extremely delicate and injury-prone one. On average it has a thickness of just a few millimetres. Now it is the first organ that can be artificially reproduced – for some years even in a fully automated process.

In practice

An acquired taste

With 100,000 smoked sausages produced each day, it is an art in itself to continuously maintain a consistent taste, colour and consistency, depending on the product type. Bösinger Fleischwaren has been doing this for decades using globally well-known smoke generators and smoke houses from Germos. In the latest product generation, standard components from Festo are increasing system availability.

In practice

Maximum pleasure, minimum consumption

Energy-saving measures are a cornerstone of the corporate philosophy of global firm Unilever. The company is now significantly reducing its compressed air consumption on a machine producing Magnum ice creams by using the new energy efficiency module MSE6-E2M.

In practice

Colorful combination on the transport track

Today filling and packaging thousands of bottles of perfume, tomorrow just a few tubes of cream and the day after batch size 1 – everything on one and the same system. How this works is demonstrated by the Multi-Carrier-System MCS®, a joint project of Festo and Siemens, put to work in a filling and packaging machine from the machine manufacturer Optima.

In practice

Staying on track

The track and camber of vehicle axles has a major influence on driving behaviour. In automotive production, track and camber adjustment used to be a time-consuming, manual process. The current generation of machines from AuE Kassel GmbH performs fully automatic track and camber adjustment in less than 60 seconds. Festo components guarantee precision and speed in this process.

In practice

Make some room!

With the “Breakthrough Generation of Machines” from Italian packaging machine manufacturer Cama, manufacturers of consumer packaged goods and pharmaceuticals are experiencing a completely new feeling of space in their factories.The new machines from Cama take up one third less space—thanks to the valve manifold concept CPX/MPA.

In practice

Test passed - compact precision

Mobile electronic devices are developed in highly automated processes. Yet their touchscreens and keys are generally still tested manually. PKC Electronics decided to go in a completely new direction with its Chameleon test platform. It offers automated, fast and reliable testing of mobile devices using different adapters. The mini planar surface gantry EXCM is completely in its element in this environment.

In practice

As precise as a Swiss watch

The Swiss watch industry protects the legendary reputation of its watches with the quality label “Swiss Made”. This level of quality can only be achieved with fast and accurate automation equipment. This led Amax Automation AG to create a multifunctional palletiser – with robotic and handling systems such as the ready-to-install delta robot EXPT from Festo.

In practice

Hot recycling coolly calculated

Disposal and fuel costs are an important competitive factor in the steel industry. Industrial waste management company Diproinduca operates a highly productive recycling plant for waste from blast furnaces on the site of the ArcelorMittal steelworks in Mexico. Festo provided a complete solution spanning several levels of the automation pyramid for the plant.

In practice

Minimalism

Bringing together all the factors important for success in one automation solution is no easy task. The aim of handling a large range of batch sizes is in direct conflict with the requirement for a lean budget. However, these conflicting demands can be reconciled, as the mini H-gantry EXCM from Festo shows.

In practice

Getting to the point

The production of sensors for the automotive industry requires increasingly sophisticated solutions. A new machine concept developed by IPTE Factory Automation enables the fast and reliable soldering of printed circuit boards in the plastic housing. The ready-to-install industrial robot from Festo used in the concept makes cycle times of less than three seconds possible, despite a moving mass of more than 60 kg.

In practice

Quick changeover

Industrial multi-needle quilting machines add a wide range of stitched patterns to mattress covers. Up to now, the stumbling block to quick pattern changes has been the need to manually adapt the needle configuration. A new quilting system from Emil Stutznäcker facilitates customised, program-controlled selection of individual sewing positions from a bank of sewing units. A cylinder/valve combination developed by Festo optimises the assembly, changeover and upgrading of systems.

In practice

Five hundred cylinders at the same time

Even though automation technology has become highly sophisticated, there is always potential to make processes even better. A stacking system for blanks shows how even the smallest of innovations in pneumatic cylinders and valves can result in a major leap forward in safety and efficiency.

In practice

Gentle, low-vibration testing

Fuel cells offer great hope for sustainable power generation. They have an extremely wide range of applications. In a new system for the quality assurance of bipolar plates, electric cylinders EPCO help to prevent vibration to allow continuous testing with short cycle times.

In practice

A Swedish recipe that really hits the spot

The fact that spot welding is becoming ever faster and more reliable is illustrated by a customer-specific solution installed at Volvo in Sweden. The ingredients for this special Swedish recipe are electric actuator technology and vision systems from Festo, linked to the CPX automation platform. This means more reliability in the production of the sheet-metal components for Volvo car bodies, and more safety for the plant operators.

In practice

Up and away

When the material is free of stresses, the product keeps its shape. A proven method for the internal harmonization of materials is tempering. Modern thermal systems such as those produced by CeraCon GmbH do this by conveying components through heat tunnels on multiple levels to save space. In a new system, safety and axis systems from Festo are used to optimize the stress relief process for car headlights during tempering.

In practice

Leakage detection in practice

Festo Energy Saving Services reduce the operating costs of industrial plants the world over. Hidden sources of errors can be found by analysing compressed air generation, consumption and quality as well as through targeted leakage detection. At Tate & Lyle in the Netherlands, the energy efficiency experts uncovered losses of 6,000 l/min.

In practice

Air is money

Well-organised energy management increases the efficiency of pneumatic systems and components. It provides protection against gradually increasing compressed air losses and ensures a long-term gain in performance through the integration of new technical developments. Accurate analyses form the basis for lower energy costs.