Machinery Modernization Case Studies

Discover how our custom automation integrations and mechanical retrofits have transformed legacy wire and cable lines into high-yielding, modern assets worldwide.
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Discover how Bemos Automation transforms complex manufacturing challenges into measurable success.
From comprehensive mechanical retrofits to intelligent PLC/SCADA integrations, explore our real-world engineering projects that have minimized downtime, maximized output, and delivered rapid ROI for cable and wire manufacturers worldwide.

Project 1:
Revitalizing a Legacy Extrusion Line for a European Cable Manufacturer

The Challenge
A mid-sized European cable manufacturer was struggling with a 15-year-old extrusion line. The legacy DC drive systems were causing inconsistent tension control, resulting in irregular insulation thickness and a high material scrap rate of 12%. Additionally, obsolete electrical components led to frequent unplanned downtime, severely capping their daily production capacity.
Our Approach
Bemos Automation engineers conducted a complete mechanical and electrical audit. We executed a full structural retrofit, replacing the outdated DC motors with high-precision AC Servo drives. To provide intelligent control, we designed and installed a brand-new, CE-compliant electrical cabinet integrated with a state-of-the-art Siemens S7-1500 PLC and a custom-developed SCADA touch-interface for real-time process visualization and alarm management.
The Results
+35% Production Speed: The new servo synchronization allowed the line to run significantly faster without compromising quality.
80% Scrap Reduction: Enhanced tension control dropped the material scrap rate from 12% to under 2.5%.
Rapid ROI: The client achieved a full return on their retrofitting investment within just 9 months, avoiding the multi-million dollar cost of a new extrusion line.

Project 2:
Comprehensive Automation & Safety Upgrade for a Rigid Strander Line

The Challenge
A major wire producer in the Middle East faced critical reliability and safety issues with their heavy-duty rigid strander line. The original relay-based control panels were failing frequently, causing over 20% unplanned downtime per month. Furthermore, the legacy machinery did not meet modern global safety standards, presenting a significant risk to floor operators.
Our Approach
Our team engineered a complete lifecycle upgrade. We completely dismantled the obsolete control panels and replaced them with a modern, intelligent automation architecture. We integrated advanced safety protocols, including automated light curtains and fast-response emergency braking systems. A user-friendly HMI (Human-Machine Interface) was deployed to give operators precise, centralized control over the stranding process and instant diagnostic data.
The Results
95% Reduction in Downtime: The transition from physical relays to robust PLC logic virtually eliminated electrical faults.
100% Safety Compliance: The integration of modern safety architectures ensured zero operator incidents and full compliance with international safety regulations.
+20% OEE Boost: Overall Equipment Effectiveness increased dramatically due to continuous, uninterrupted operation and faster setup times via the new HMI recipes.

Write Your Own Success Story with Bemos Automation

Every production line has hidden potential. Whether you are dealing with excessive downtime, high scrap rates, or outdated safety systems, our engineers have the expertise to solve it.