High spare part availability thanks to automated production
What began in 1893 at GEA's Oelde site, with the construction of the first manually operated centrifuge for separating milk and cream, is now an indispensable part of modern industry.
Whether food, beverages, pharmaceuticals and vaccines, chemical and marine products or clean water: anywhere liquids have to be processed, a separator or a decanter is at the heart of the production plant. Today, Oelde is GEA's largest production site worldwide with a total of 1,900 employees. Up to 120 centrifugal separators are produced here every month, from development to final acceptance. The centrifuge manufacturer ensures high productivity and quality with equally modern machine tools, including 15 models from DMG MORI – from 5-axis simultaneous machining centers to turn-mill centers with maximum process integration. The latest acquisition fits perfectly into the future-oriented production: on a CTX gamma 3000 TC with MATRIS robot, the drive production department produces spindles in a wide range of variations –including deep hole drilling, grinding and in-process measuring.
Up to 500 components are required to manufacture one of the complex centrifugal separators, from the drive to the bowl and its inner workings. “As the components to be manufactured are adapted to the customer's application, many components are produced in a batch size of 1; after all, we are in the special machine building business,” says Dennis Hartmann, Head of Industrial Engineering in the Separators Business Unit, giving us an idea of the production effort involved. Consistent process optimization enables cost-efficient production in the traditional plant. The largest and most modern hall in Oelde has an automatic storage and transport system with 5,000 pallet stations. The individual components are brought together in an efficiently synchronized flow assembly. After assembly, all separators undergo practical testing on 16 test benches. “Another important part of our daily work is supplying our customers with spare parts,” explains Dennis Hartmann. GEA's more than 50 sales and service companies regularly determine their requirements and commission the plant to produce the parts needed. This also applies to drive products – including gear and belt drives as well as (in the most modern version) integrated direct drives. “We manufacture the corresponding components in batch sizes of up to 50 parts.” In addition to turning and milling, machining of the complex and high-precision spindles includes deep hole drilling and grinding, as well as gear milling for some variants.
Future-oriented focus in production
“We implemented our philosophy of integrating as many processes as possible and automating spindle production in 2023,” says Dennis Hartmann, looking back on the purchase of a CTX gamma 3000 TC with a MATRIS robot. Following positive experiences with previously installed machine tools from DMG MORI, those responsible in Oelde once again found what they were looking for in the market leader's product range. “The high degree of technology integration and the automation solution from a single source were the deciding factors in the market comparison.” Test runs were also convincing and the proximity to the DMG MORI factory in Bielefeld was a major advantage during the project. There is another point that stands out: from process integration and automation to digitalized processes and sustainable management, GEA is pursuing exactly what DMG MORI is also aiming for with its Machining Transformation (MX) – a future-oriented approach to the entire production process.
6-axis turning-milling, deep hole drilling, grinding and in-process measuring
With the automated CTX gamma 3000 TC, GEA has firstly replaced an old machine and secondly made spindle production significantly more cost-effective. “Previously, machining processes were required on milling machines, turning centers and a cylindrical grinding machine. Then there were the idle times in between,” explains Marcel Richter. As machine operators, he and Patrick Wieder are responsible for operating the production cell. Their practical experience was incorporated into the CTX design. The turn-mill center for 6-axis complete machining integrates all the different processes, including grinding, in one work area.
“The result is significantly shorter throughput times. And we can make better use of the other machines at the same time,” says a satisfied Patrick Wieder. The in-process measurement also makes life easier for quality control. Deviations are corrected in the program so that the values remain consistent throughout the batch. “We can even determine tool wear automatically using a measuring fixture. If the actual value exceeds the target value, the tool is replaced by a sister tool.”
Optimum equipment for process reliability and flexible automation
The CTX gamma 3000 TC was selected to enable reliable and flexible machining. “The size was necessary because we machine spindles that are up to 1,000 mm long. We need sufficient travel in the X-axis for deep hole drilling,” says Patrick Wieder, explaining the choice of model. A powerful coolant pump prevents the accumulation of chips that would interrupt the process. Another special feature is a separate compartment for oversized tools in the right-hand section of the work area. “This allows us to carry out the grinding process with larger wheels, for example, which saves time and reduces tool costs,” explains Marcel Richter. The biggest advantage is, of course, the fully automated production of entire batches. The MATRIS system was designed to be loaded via four pallets. The robot takes the raw parts and aligns them so that it can clamp them correctly in the chuck and steady rest. The finished parts are then placed back on the pallet. The close cooperation with DMG MORI was also evident where programming is concerned. With the installation of the CTX gamma 3000 TC, GEA was also a pilot customer at the Oelde site as part of the development of OP Workbench. “The software significantly simplifies the work involved in workshop-oriented programming,” says Marcel Richter, assessing the added value in terms of time. “OP Workbench uses master programs to which we add set-up parameters such as the length of the chuck. Machining sequences are placed in the right place in the program using drag & drop.” The resulting operation sequence is sent to the NC, where the user enters the G-codes to produce the workpiece. Patrick Wieder also sees an advantage in the display:
“A split screen shows the executed operations on the left and the corresponding G-code on the right, while a live view of the operations being performed at the main or counter spindles further enhances the understanding of the programs.”
Solution-oriented collaboration throughout the entire project
Process optimization in Oelde is a continuous process that will also be the central issue for future new acquisitions in the factory. “Whether as a replacement for old machines or as part of technology integration – our investments in production are always driven by innovation,” says Dennis Hartmann, explaining the motivation behind new acquisitions. “A solution-oriented partner like DMG MORI is a great support, especially for large projects that can extend over a period of up to two years, as in the case of the CTX gamma 3000 TC.”
GEA Westfalia Separator Group GmbH
Werner-Habig-Straße 1
59302 Oelde, Germany
www.gea.com/separation