From Integration and Support to Full Turnkey Solutions

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KlareTech combines years of experience across a massively broad scope of machine building and project engineering with a carefully selected network of system integrators and various industry specialists as well as our market leading global partners to bring the most comprehensive and cutting edge mechatronic offering to the African market.

With skills covering all of the various mechatronic disciplines including electronics design and integration, software engineering and mechanical engineering KlareTech is positioned to tackle any automation project. Our team's diverse experience covers hundreds of individual projects from automotive, confectionary, packaging, bottling, mining, power generation, textile manufacture and plastics industries.

KlareTech has been involved with filling machines, injection and blow molding machines, robots in both automotive and packaging environments, pump stations, winders, counting and batch handling machines, conveyoring and material handling, mining machinery, fermentation controllers, condition monitoring for bearings, labeling, printing presses and saddle stitchers, shrink wrappers and many others.

We have worked in all of the major industries including pharmaceutical, textile, food and beverage, packaging, plastic, metal, mining and wood working among others.

Please feel free to contact us for a meeting regarding your specific needs at any stage! 

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Our projects and engineering team boasts an impressive CV having been involved in the following projects:

Plastic handle applicator - Handling 2750 bottles per hour, our latest turnkey solution for applying plastic handles to PET bottles before they are filled looks set to become a serial production machine

Woodfirst - Alpine shovel yarder - complete electronic control system and software development

KR Plastics - Software application for a soft tube box packing machine

SmartMould Injection Mould upgrade kit - Complete control system upgrade of any injection moulding machine installed for multiple customers in South Africa including Venture, Boxmore and Astrapak

Caxton - Turnkey board identifier and seperator for a label cutting machine

Herber Plastics - Complete control system upgrade of dual stage extrusion blow moulding machine

Polyoak Blowpack - Control system upgrade of a dual stage extrusion blow moulding machine with every possible extra

ALSTOM PAC - Water supply and flow control system for Medupi power station using wireless information transfer over 5km for analog and digital signals

'Top Secret' - Turnkey customised Electronic Sensor manufacture for metal detection

Aberdare Cables - Cable Printing Machine

Kapa Biosystems - Aseptic Filling Machine

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Volkswagen South Africa

A1 Engine Line A4 Dress up, Rear Axle, Front Axle and Power Train Lines
PQ24 Front Axle, Rear Axle, Power Train and Sub-Frame Lines
PQ35 Front Axle, Rear Axle, Power Train and Sub-Frame Lines
EA153 Engine Line installation and volume increase

Daimler Chrysler South Africa

W203 Axle Line
W203 Final Assembly - Wheel Bolting, Shock Fitment, Engine Marriage

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ZF Lemforder South Africa

E46 and E90 Axle and Differential Line
E90 Axle Assembly 4x4 upgrade
Spring compression and strut assembly facility
E46 and E90 Dynamic Brake Adjustment Facility

Ford Motor Company

Rocam Engine Line
Rocam Head Line

BMW South Africa - Wheel Bolting Facility

Cadbury - Various Confectionery Machines

 

See the links below for more information on our recent interesting projects

Blow moulding machine upgrade using B&R

Seamless Integration of complex extras

In our latest onsite upgrade KlareTech went all the way.

This dual carriage extrusion blow moulder had every possible additional feature - Takeout robots, In-mould labelling robots, hydraulic scrap remover and needle-blow. All of these features were seamlessly integrated into the B&R blow moulding control platform running on a Power Panel 400 embedded HMI/PLC with X20 IO.

An 8-layer parallel control sequence means that every movement is adjustable to ensure flexibility for handling the most complex tasks.

The below video shows one of the most complicated bottles currently blown in the South African market running smoothly with a cycle time of 14 seconds all controlled with our upgraded system.

KlareTech bolt on solution

Speed and Accuracy from B&R stepper motors

Caxton approached us to develop a system to identify a 2mm thick piece of cardboard in a stack of labels based only on a slight difference in colour between the edge of the labels and the edge of the cardboard and then to pneumatically seperate the stack at the cardboard.

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The system had to be reliable, accurate, fast, and fit into a small space under an existing machine. It was also necessary for the system to handle different colour labels and cardboard seperators.

Turnkey machine built to press handles on PET bottles

2700 bottles per hour with a footprint of less than 4 square meters

KlareTech's latest turnkey project is set to become a serial production offering. The handle press applies handles to PET bottles before they are filled at a rate of one handle every 1.33 seconds.

The unique challenges for this machine are feeding the handles in a fast an economically viable way, and providing support to the sidewalls of the bottle so that it doesn't collapse during the application of the handle.

Our unique approach to feeding the handles to the machine from hand-packed cartridges allows handles to be prepared in advance or during operation. An XY stage driven by B&R servo motors gives fast precise positioning of the bottle support and handle press mechanisms in relation to the bottle and allows it to be cleared out of the way of the next incoming bottle at high speeds. Bottles are supported at the strongest part with another unique solution that ensures no load is carried by the sidewalls of the bottle during the handle application.

The machine is controlled using a B&R control system which is completely integrated end-to-end for plug and play maintenance and simple onboard diagnostics.

 

Injection Moulding Machine Upgrades

B&R SmartMould

SmartMoldPanelComplicated electrical control systems, although ruggedized to varying extents, are usually based on similar technology to PC's and expecting them to perform day after day in the often harsh production environment for years on end is of course, unrealistic.

It is normal for the downtime on machines with electronic control systems to increase exponentially as a function of time due to the decreasing availability of components, greater difficulty in troubleshooting as problems become more stochastic, complex and interlinked and the increased chance of failure of these components due to years of daily wear and tear. These challenges are compounded by the fact that older components generally become more expensive as the volumes of their global use decrease. Constantly repairing these systems is akin to trying to repair a 10 year old computer at an ever increasing price with ever worse reliability and functionality as the end result. As with the computer it makes much more sense to simply replace the control system with a new one.

Succesful local installations include machines for AstraPak, Venture and Boxmore.

Dual Carriage Extrusion Blow Moulder Upgrade

Fastest possible turnaround with B&R control system

KlareTech recently completed a control system upgrade on an old dual carriage extrusion blow moulding machine.

blow-moulding-upgrade-hmiThe upgrade took only 5 days from arrival on site to full production! This super fast turn around time was made possible by the pre-written B&R blow moulding software and embedded control system and HMI combination of the B&R Power Panel range.

Turnkey test equipment by KlareTech

Solenoid test bench

When one of our customers needed to thoroughly test a component of their machine before using it the field they turned to KlatreTech to find the solution.

Using a B&R X20CP1486 PLC and a KlareTech custom-built 550VDC drive we were able to create a system that not only monitored various elements of the solenoid such as temperature in several different places on the solenoid as well as stroke length, stroke time, power consumption and current drawn with each activation of the solenoid but also provided the control for the solenoid to simulate field activities.

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B&R Water supply control solution

Successful FAT for Medupi Raw Water Tie-in

During November 2013, ALSTOM PAC South Africa successfully completed the Factory Acceptance Test (FAT) on the autonomous controller for the temporary raw water tie-in point situated 5 km away from the Medupi power plant site (Fig. 1). The raw water tie-in facility is a critical part of the activities associated with firing of the first unit.

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In addition to the main project, Eskom awarded the raw water tie-in automation contract to PAC in 2013. Due to the tight subproject schedule derived from the overall project acceleration, the X20 hardware platform using POWERLINKâ„¢ fieldbus from Bernecker & Rainerâ„¢ (which is used already for Medupi and Kusile turbine controllers Controsteam), was selected. The Wireless link to DCS has been implemented using RadioLinx equipment from ProSoftTM