Planning Posted on 23. January 2025.SUCCESS THROUGH FORESIGHT!The planning of a coating system forms the foundation for our targeted actions.Every step in a project requires meticulous planning. Whether it is a feasibility study, project implementation, or relocating a facility – planning determines success.Many believe that project management is the most important aspect when building a coating system. While this holds merit, we believe that the planning phase before actual implementation is even more crucial. The project phases can be likened to states of matter:Gaseous: In this phase, everything is highly flexible, and numerous ideas are considered. Variants are tested, and new solutions are developed.Liquid: At this stage, the project gains momentum, and with ink comes numbers and plans. The contract is eventually signed by all parties. Changes are still possible at this point.Solid: The system is under construction, and modifications become difficult. Planning errors now have severe consequences.Thus, we place great emphasis on the system’s conceptual design, where the system’s success is mapped out. OUR 8-STEP PRE-PROJECT PLAN1. DETAILED ANALYSIS:We examine processes, material flows, part spectrum, logistics, etc., aiming to achieve a comprehensive overview.2. CALCULATION OF OPERATING COSTS:Using our tool, we project future operating costs today. We can also calculate your current costs to establish a solid foundation.3. CUSTOMER BENEFIT ANALYSIS:Based on collected data, optimization points are identified, and potential opportunities are highlighted.4. PROOF OF SPECIFIC SAVINGS:A comparison of the actual and desired states are shown in an overview, considering also savings and potential risks.5. PROFITABILITY ANALYSIS:An initial calculation of economic efficiency is conducted.6. PRESENTATION OF VARIANTS:There is not just one solution. Through iteration and alternative approaches, we find the best solution together.7. PROFITABILITY REPRESENTATION:For your CFO, we prepare key figures such as cumulative savings over the lifecycle, Internal Rate of Return (IRR), Net Present Value (NPV), and Payback.8. PRESENTATION OF RESULTS:Results are summarized in a clear document for the board or supervisory board. A summary of variants provides a solid basis for decision-making. SimulationsPinCHThermal simulations showcase energy consumption and optimization. Learn more: PinCH analysis SimLackOur proprietary software investigates entire systems concerning conveyor technology. Unlike market-available tools, we emphasize physics over graphics. This simulation of the coating system allows proof of concept and identifies weaknesses. Potential issues can be simulated, and solution strategies developed. Contact our sales team for more information: Sales Switzerland, Austria, and other countriesRamon KramisHead of SalesPhone: +41 41 464 35 04kramis@luterbach-ag.chSales GermanyMarkus GebauerSales EngineerTel: +49 5681 8049971gebauer@luterbach.gmbh
General contractor Posted on 23. January 2025.Looking for a single point of contact? WE have got you covered!As a turnkey or general contractor, we deliver complete coating systems from A to Z – tailored, smart, and energy-optimized. Beyond planning, we also realize the entire coating facility. We bring your vision to life, managing interfaces with project partners. OUR SERVICES:Initial consultationsProject engineering: Feasibility studies, make-or-buy analysesCost optimizationEnergy optimization with PinCHClient representationInterface coordinationProduction, assembly, and commissioningTrainingProduction supportFull compliance with comprehensive risk analysisMaintenance and servicing Your benefits: Our all-inclusive package!Cost security: Enjoy peace of mind with our fixed-price guarantee.Expert consultation: Innovative solutions tailored to your needs – we think outside the box!Schedule reliability: Trust our experienced project managers to deliver every element on time.Uncompromising quality: We partner with trusted, long-standing collaborators to ensure excellence in every detail.WHAT OUR CLIENTS SAY:“For us, reliability, innovation, and trust have always been essential. We found these qualities in Luterbach. We appreciate the out-of-the-box thinking and the value-added solutions provided. The overall package convinced us in the end.”Christoph Mehler Former member of the Executive Board and Head of Production at Schmid GmbHContact our sales team for more information: Sales Switzerland, Austria, and other countriesRamon KramisHead of SalesPhone: +41 41 464 35 04kramis@luterbach-ag.chSales GermanyMarkus GebauerSales EngineerTel: +49 5681 8049971gebauer@luterbach.gmbh
Automation Posted on 27. January 2025.With our central control system, you have full command over your processes!Simplified system controlOur control concept makes it easy to get started with your new system. It offers a comprehensive overview of the entire setup, integrating components like pre-treatment, chemical dosing, dryers, ovens, cooling zones, and the conveyor system into one platform.If you can operate a smartphone, you will be able to use our solution right away! Connect your ERP with the systemProvide your staff with the right information, in the right place, at the right time – make your process management smart!Our SmartMES coat supports the powder and liquid coating processes of our systems, enabling you to use the system more easily and efficiently while continuously optimizing your processes.SmartMES coat consists of individual modules that can be expanded at any time with customer-specific functionalities.iDIP as Platform BaseAs an official integration partner of iDIP Solutions, we offer you a modular and user-friendly solution for digitizing your production processes with the iDIP platform. The platform enables seamless integration of machines, sensors and peripheral systems.The advantages of the iDIP platform for our customers are:No-code/low-code development: fast individual applications, workflows and customizations with the App Designer – you can also make simple adjustments without any programming knowledge.Modular structure: adapt the platform flexibly to your specific requirements by choosing from various standard modules. – Live, immediately without a long development time.Combine many interfaces: Network powder coating with logistics, powder storage, quality assurance, etc.Mobile integration: Use the iDIP mobile app for Android and iOS to scan barcodes and receive notifications in real time.Real-time data and dashboards: Keep an eye on key performance indicators at all times and make informed decisions based on up-to-date data. You are currently viewing a placeholder content from YouTube. To access the actual content, click the button below. Please note that doing so will share data with third-party providers. More Information Unblock content Accept required service and unblock content
IoT Posted on 27. January 2025.smart:IoT PlatformDashboardsThe smart:IoT Platform introduces new opportunities for efficiency enhancement, monitoring, and control in the (coating) industry. The platform enables the easy creation of dashboards specifically tailored to production, controlling, and many other applications. Thanks to our flexible solution, individual customization is straightforward. You can design your dashboards according to your own requirements, optimizing the monitoring, analysis, and control of processes. Our platform provides the freedom to display relevant information and key metrics for your business clearly and attractively. This platform allows a clear overview of plant performance, helping you increase efficiency and lead your company into the digital future. IoT platform dashboard Logging and data exportOur platform records all transmitted values and allows their export in various formats such as Excel, Print, and more. This enables you to save and process collected data in the desired formats. Whether you need the information for in-depth analyses or reports, our export function provides the flexibility to use the data according to your needs. Simply select the data and export it into the desired format to create the necessary documentation or analysis. With smart:IoT, you have full control over your data and can effectively use it to make informed decisions and optimize your business processes.Alarm managementOur platform allows the triggering of alarm chains with escalation levels across various channels such as SMS, email, phone, and more. You can set up customized prioritization and forwarding of alerts to the appropriate personnel. In the event of a disruption or critical event, notifications are automatically sent via SMS, email, or phone to responsible staff. By establishing escalation levels, we ensure that alarms are handled promptly and no critical information is overlooked. Our diverse communication channels ensure that the alarm system operates effectively and reliably, enabling swift action to address and resolve issues efficiently. VPN remote accessUsing the IoT gateway, we establish a secure remote connection to the plant network. The smart:IoT Platform allows you to create a protected connection via the IoT gateway and access the systems even when you are not on site. This remote connection enables you to access essential information and functions anytime, anywhere. At the same time, we ensure the security of your data and protect your plant network from unauthorized access. Our solution allows for effective monitoring of systems, remote diagnosis of issues, and, if necessary, remote adjustments. The IoT gateway provides a convenient and secure way to interact with your systems and fully leverage the potential of the Internet of Things. Online access to visualizationsWith smart:IoT, we enable direct operation of Siemens Simatic HMI devices via a web browser. You can easily access the HMI interface and control the devices directly from any web browser, without additional software or special access routes. This web-based operation gives you the flexibility to access HMI devices from various devices such as tablets, mobile phones, or laptops/PCs. This allows for system control and monitoring anytime, anywhere. Our solution simplifies the operation of Siemens Simatic HMI devices, offering an intuitive and user-friendly interface for managing your systems.
Painting robots Posted on 27. January 2025.Batch size 1, skilled labor shortages, cost pressures – more automation!Achieve a flawless finish automatically.Painting robots are taking on more and more tasks in modern coating systems.We design tailored solutions in collaboration with our customers and while we remain flexible regarding the robot brand, we are happy to provide expert recommendations.Robotic solutions can be adapted to nearly any application area.Contact us today and optimize your painting processes with smart automation solutions! What application methods are possible?Actually all of them: from atomizers to electrostatics (ESTA), rotary bells, and powder coating. How are painting robots programmed?Depending on the application, several programming methods are available:Point2Point programming: The control unit is used to move the robot from point to point and teach in. This method is rarely used today.Offline programming: The painting booth, robot, and workpiece are modeled in 3D within a virtual space. Intelligent tools allow you to “paint” the part digitally on a PC. The program is then tested on the real system and optimized if necessary.Self-Teach programming: Designed for simpler but highly variable geometries, this method uses a modality assigned to the robot. Upon entering the booth, the workpiece is 3D-scanned. For example, in the case of a window, the interior, exterior, and front surfaces are identified. The software instantly generates the program, and the robot begins painting. This is an ideal solution for large hanging assemblies.Teach-In programming: The painter “guides” the robot by hand, showing it how to coat the part. The robot records these movements and replicates them precisely, including the painter’s natural gestures. This approach is especially effective for complex or frequently changing parts, as commonly encountered by contract coaters. Who can program a robot?This depends on the task and the selected programming method: With a 3D tool, virtually anyone can learn to program a robot.Teach-in programming is best performed by experienced painters.Self-teach programming is automatic and requires minimal to no interaction. Integrated with our SmartMES, modalities are automatically assigned to the hanging assembly. How are programs managed?Programs are generally stored centrally and ideally called up automatically by the control system, enabling full automation.However, it is crucial to consider numerous parameters, such as variations in paint types or coatings, which may require additional programs. Properly managing these complexities becomes effortless with our SmartMES, ensuring smooth and reliable operations.3D Laserscanner SolGel painting robot Master controlRobot control station Control station
Maintenance and support Posted on 23. January 2025.Optimal availability through regular maintenanceOur program includes:spare partsmaintenanceservicerepairsWe go beyond planning, designing, manufacturing, and commissioning your system by offering comprehensive support and maintenance services. PerformanceTo ensure long-term high productivity and availability of your system, we offer preventive maintenance for the entire setup. Our service options range from one-time classic maintenance to full-service contracts, which can be scheduled at fixed intervals (monthly, quarterly, semi-annually, or annually). Regular maintenance minimizes disruptions and prevents extended downtimes.Our experienced staff, familiar with your system and similar installations, can quickly identify potential weaknesses in connections. This expertise helps you reduce costs and avoid unnecessary downtime.In case of malfunctions, we respond promptly, resolving issues efficiently thanks to our team’s deep knowledge. Remote supportLeveraging cutting-edge information and communication technologies, we provide innovative service solutions to streamline operations. Through remote maintenance, our specialists can often restore your system or at least analyze error data without being on-site. This allows for faster and more targeted interventions.Analyzing operational and error reports also helps in planning preventive maintenance more effectively. Advantages of our service offeringsincreased production outputenhanced product qualityreduced energy consumptionlower wear and tearPreventive maintenance and continuous system optimization form the foundation for sustained operational readiness and smooth functionality of your systems.Service means security, and security ensures availability.
Retrofitting Posted on 28. January 2025.RETROFIT BECOMES SMART FIT – YOUR SYSTEM DOESN’T NEED TO BE NEW, JUST FUNCTIONALWould you like to continue using your existing coating system while bringing it up to modern standards?With a Retrofit, we upgrade your system in a targeted, efficient, and resource-friendly way. A complete replacement is often unnecessary, as older but well-maintained systems can be significantly enhanced in terms of technology and functionalitySmart Fit is our response to increasing demands for energy efficiency, production reliability and spare part availability. It takes the traditional Retrofit to the next level.Smart Fit – Added value for your SystemWith Smart Fit we upgrade your system where it makes sense. The result is a future-ready solution that delivers both technical excellence and economic value. What does Smart fit mean in practice?Smart Fit stands for smart modernization tailored to your specific needs. We focus on the following areas:Upgrading control systems, including modern HMI interfaces and integration into current communication systems like IoT or MESImproving energy efficiency through heat recovery, frequency inverters or hybrid heating systems using gas, electricity or solar energyRetrofitting safety systems to meet current legal standardsAdapting and extending existing conveyor systems, including those from other manufacturers Your benefits at a glanceLower costs compared to a new systemShorter conversion times thanks to targeted partial upgradesSignificantly extended system lifetimeReduced energy consumption and operating costsImproved spare parts availabilityLegally compliant implementation including CE marking and risk assessment Safety and responsibility clarifiedMajor upgrades to an existing system may require a new risk assessment. We take care of the entire analysis, define the necessary measures and ensure your upgraded system complies with CE requirements. This helps you avoid legal uncertainties and liability risks. Experience matters – even with third-party systemsWe have more than ten years of experience in modernising a wide range of system makes. We have also successfully replaced control systems from manufacturers such as Mitsubishi, Panasonic and Omron.HMI after the conversionInstallation of new componentsOld switch cabinetHMI after the conversion You are currently viewing a placeholder content from YouTube. To access the actual content, click the button below. Please note that doing so will share data with third-party providers. More Information Unblock content Accept required service and unblock content
Energy efficiency Posted on 27. January 2025.The painting process is one of the most energy-intensive operations, accounting for up to 70% of energy consumption in some cases.Improving energy efficiency across individual processes leads to significant energy savings.At e. Luterbach AG, we have implemented cutting-edge technologies and solutions in numerous projects to reduce energy consumption. From analysis and cost-effectiveness calculations to implementation, we handle every step for our customers. In specific projects, we have successfully achieved documented savings of several hundred thousand euros.Given the sharp increase in energy prices in recent years – and the expectation that they will continue to rise – most investments in energy-efficient systems are economically viable. Payback periods of three years or less have become the norm rather than the exception.Studies by institutions like the Fraunhofer Institute IPA in Stuttgart provide further evidence to support these claims. PinCH ANALYSISWe have expanded our capabilities with the PinCH analysis, allowing us to design even better systems.This integral method optimizes not only individual components, such as ovens, but also the entire system as a whole.By broadening the system boundaries, we can also integrate the surrounding environment-additional equipment, buildings or adjacent facilities, infrastructure like compressors, and more.This holistic approach uncovers greater opportunities and enhances potential savings.While PinCH is well-established in various energy-intensive industries, we have now integrated this method to optimize your operating costs.Several facilities have already been successfully planned using this approach, with notable results. For example, one customer received funding for the construction of a new plant due to the demonstrated energy efficiency improvements. Invest in sustainable efficiency with e. Luterbach AG and reduce your operational costs for the long term. Contact our sales team for more information: Sales Switzerland, Austria, and other countriesRamon KramisHead of SalesPhone: +41 41 464 35 04kramis@luterbach-ag.chSales GermanyMarkus GebauerSales EngineerTel: +49 5681 8049971gebauer@luterbach.gmbh
