Several successful upgrades of KARO IV ensure continued safe and efficient operation

Three KARO IV safety upgrades completed within one year by Brückner Servtec

Three times within one year, Brückner Servtec has successfully closed an age-related security gap in the previous operating system of the KARO IV batch laboratory stretching machine*, thus ensuring customer’s film developments and innovations. The systems of the American and Japanese clients are now equipped with a new programmable logic controller (PLC), fostering enhanced safety and reliability.

The challenge: Addressing a critical safety gap

Over time and after many years of good operation, the KARO IV was faced with an obsolete P350 control system from Siemens and outdated Windows XP operating system. Due to the discontinued production of spare parts and support for the operating system, a significant safety and maintenance gap for the KARO IV emerged, which had to be solved quickly to prevent equipment failure, operational disruptions, and a loss of the film quality in the samples.

The solution: Extensive electrical upgrade

In order to restore the full functionality, safety, and reliability of the KARO IV, the most effective solution is an upgrade to a programmable logic controller (PLC), which enables a new visualization and consistent, accurate control over the test film processes.  

The modernization project basically consisted of three sections:

1. The electronic modifications included adapting circuit diagrams, electronic component lists, and ordering the corresponding parts from suppliers.  
2. After delivery, extensive in-house test runs at the Siegsdorf office, are carried out to ensure correct installation and to identify any defects early, thereby saving time and costs on the customer’s site.
3. Shipping to the customer for on-site installation and commissioning, including again test runs as well as trainings of customer personnel on the new system.

During the installation of the new logic control program, the necessary disassembly of the KARO IV allowed maintenance work to be carried out at the same time, improving lifespan and efficiency of the plant, and saving time and costs for future repairs.

All in all, the upgrade process was, every time, executed seamlessly and efficiently by customer’s personnel and Brückner specialists as Richard Höpfler, installation engineer on-site for the KARO IV upgrades, states: "Due to the unique materials and technologies utilized in KAROs, special solutions are always required. I would like to thank the customers and their staff for their excellent cooperation during the installation times. The positive and helpful attitudes of everyone involved have contributed to the success of each project."

Each KARO IV has been upgraded on-site in less than five days and is now operating safely and efficiently as the following American customer feedback confirmed: “Upgrading our KARO IV has been nothing short of exceptional, carried out quickly and smoothly – really showing of the team’s commitment and expertise. Now we are back in action, operating more safely and efficiently than ever, thanks to the Brückner Servtec team.”

Also, project manager Hubert Maier looks back on three successful collaborations and adds: "The KARO IV upgrades are always a welcome change in my daily routine and therefore very special to me. Many thanks to our customer’s for their continued loyalty and trust in Brückner Servtec’s innovative service solutions."

*Batch laboratory stretching machines help in a simple and economical way to test films in both, sequential as well as in simultaneous stretching mode, for customer’s research and development. More details here.