Optimization of Machines and Production Lines
In many production facilities, machines and lines do not fully reach their potential. Often, a small change in the control program, a reorganization of the operation sequence, or an adjustment of cycle parameters is enough to significantly improve efficiency and shorten production time.
G-Flex offers comprehensive optimization of machines, conveyors, and entire production lines. We work both on individual stations and on complex systems involving multiple devices. We improve signal exchange between controllers, eliminate cycle delays, combine movements that were previously performed sequentially, and introduce logical changes to the control algorithm. Wherever possible, we synchronize operations and shift them into a shared time window.
In practice, this results in shorter cycles, a higher number of finished units, and better use of available resources. Each optimization is preceded by process analysis, baseline measurements, and tests confirming the expected results.
Case Study: Optimization of a KHS Palletizer
Machine: Palletizer for shrink-wrapped beer packs (EUR pallet, 8 layers)
Industry: Beverage and brewing
Goal: Reduce cycle time and increase throughput without mechanical modifications
Scope of work:
- analysis of optimization potential,
- step-by-step improvement plan,
- modification of the machine’s PLC program,
- speed adjustment within safety limits,
- optimization of sequence and external signal response,
- comparative testing and time measurements before and after implementation.
The cycle time was reduced by over 12%. The client achieved a real increase in production capacity without investing in new equipment. Over the course of a year, this translated into more than 21,000 additional pallets prepared for shipment, significantly improving the efficiency of the final stage of production.
Parameter
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After
Conveyors are the heart of efficient production
Although often overlooked, conveyors play a key role in ensuring the smooth and efficient operation of a production line. They are responsible for maintaining a continuous flow of product between machines, ensuring smooth pickup and consistent delivery speed. Well-configured conveyor control avoids excessive pressure and minimizes the risk of containers tipping over. A lack of precision in this area can result in product damage, unstable machine operation, and unnecessary downtime.
We have many years of experience in this field. For years, we have been designing and implementing proven conveyor control systems, now used in dozens of production facilities. Our specialists understand the real challenges of product transport and know how to solve them effectively through control logic, synchronization, and inter-machine communication.
Many of our clients benefit from our conveyor optimization services and observe measurable improvements. One example is a project where we recommended the installation of our proprietary G-Liner alignment controller. This single change increased the line’s efficiency by 14 percent. It clearly shows that effective conveyor operation is not just about reliable mechanics but, above all, about intelligent control.
