New tools optimise workflows

SCHULZ software for more efficient processes

Where information flows faster, better solutions emerge. This also applies to workflows between engineering, programmable logic controller (PLC) development and the programming of operator interfaces, also known as human-machine interfaces (HMI).

To support this, our PLC team has developed its own software tools that automate, structure and simplify workflows. “The idea emerged directly from day-to-day project work,” explains Günter Nobis, head of PLC/HMI software development. “Recurring requirements, small optimisation opportunities and typical coordination challenges were systematically analysed and transformed into more efficient processes.” Developed and tested from practical experience for practical use, the tools were created in close collaboration with our engineering department. In the future, engineering documentation will be able to be imported directly into the system.

The result: program modules, visualisations, menu structures with screen navigation, alarm messages and operator notifications are generated automatically by the new software solutions. At the same time, transmission errors are minimised, processes become more transparent and clearly structured, interfaces are easier to manage and a consistent data foundation is created for everyone involved.

In addition, the tools can be integrated seamlessly into existing software environments and process structures. We are currently enhancing them with AI-supported programming capabilities to further accelerate software development. Information is no longer lost and modifications can be implemented quickly and efficiently. Günter Nobis highlights another advantage: “This allows us to integrate our customers’ ideas and requirements into workflows much more effectively and from a much earlier stage.”

For our customers, this means more user-friendly interfaces, shorter coordination times and more flexible, needs-based project delivery. Digital tools such as these make a direct contribution to the quality and efficiency of our projects.

Through meticulous preparation, we prefabricated all components, installed cabling and assembled control panels in advance, allowing us to make optimum use of every second during the conversion.

Günter Nobis, head of PLC/HMI software development, SCHULZ Systemtechnik

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A perfect finish with JESSAT

New to the SCHULZ Group

A valuable addition to our automotive portfolio: since 2025, JESSAT GmbH has been part of the SCHULZ Group.

JESSAT brings many years of experience in industrial automation, with a particular focus on paint shops, pre-treatment systems, e-coat plants, drying systems and control solutions. This expertise adds valuable know-how that will significantly strengthen future projects.

From the very beginning, our partnership has been characterised by mutual trust and a shared commitment to common goals: making processes more efficient, developing innovative solutions and delivering real added value for our customers. By combining our expertise in automation and manufacturing with in-depth process engineering knowledge, we are creating a new level of specialisation in paint shop integration.

We are delighted to welcome a team that brings creativity, technical excellence and a strong commitment to quality – ideal foundations for exciting joint projects and powerful solutions for the automotive industry.

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Marcel Buerschaper

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Turning energy into energy

Heat recovery systems for industrial applications

Whether from wood waste, process heat or geothermal energy, the opportunities for sustainable energy generation are diverse – and increasingly in demand.

Together with companies from the energy and industrial sectors, we are currently delivering several customised heat recovery solutions. One example is a biomass energy centre, where wood waste such as used pallets is shredded and utilised directly on site to generate heat. Materials that would previously have been discarded are now being transformed into a valuable energy source. In another project currently under construction, waste heat from a high-temperature industrial furnace is recovered via a flue gas heat exchanger to support the heating system of a steelworks. This significantly reduces both emissions and the consumption of fossil fuels.

We are also implementing a forward-looking energy concept for a major mineral water producer. A new biomass combined heat and power plant will supply the majority of the process heat required, including heat for bottle cleaning operations. As part of the new boiler house construction, SCHULZ is delivering the complete building services package, including electrical engineering, instrumentation, control technology and software programming. The main challenge: “Production continues at full capacity all around us,” explains Simon Köppe, automation project manager at SCHULZ Wallenhorst. “That is why the modernisation is being carried out in a series of carefully planned construction phases. Projects like this require absolute precision and excellent timing.”

Another project is being delivered at one of Germany’s largest exhibition centres. There, the existing heat supply for the entire site is being decarbonised, with all gas-fired generation systems being replaced by large-scale heat pumps using groundwater as their energy source. The wells for the groundwater pumps extend to depths of up to 30 metres and will make renewable energy available for future operations. Our team on site has already completed the full cabling infrastructure, control panels and building services systems for the wells. Further project phases, including the electrical installation for the new heat pumps, will follow in subsequent installation stages. Simon Köppe explains: “Flexibility and the ability to respond quickly are essential here as well, because all work must be carried out around ongoing exhibition and event operations.”

All of these projects share a common goal: making energy use more efficient, conserving resources and developing tailored solutions for a sustainable future.

The most sustainable energy is often the energy that already exists. Our job is to make it usable in an intelligent way.

Simon Köppe, Project manager, SCHULZ Wallenhorst

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SCADA migration under cleanroom conditions

Complex modernisation in pharmaceutical manufacturing

The pharmaceutical industry operates to the highest standards. Strict hygiene requirements and complete data traceability are essential.

This was precisely the environment in which we carried out the migration and modernisation of a SCADA system for one of Poland’s largest pharmaceutical manufacturers while production remained fully operational. The primary objective was to transfer the existing visualisation and data acquisition functions to a new, independent system.

Working closely with three teams – SCHULZ, Rockwell and the customer’s IT department – we installed and configured new servers. At the same time, we modernised visualisation systems, replaced control components and carried out comprehensive IQ and OQ validation procedures. New operator interfaces and additional HMI panels improved system visibility and ensured local operational control. Thanks to our extensive pharmaceutical expertise, we successfully completed the migration during ongoing production despite stringent hygiene, cybersecurity and scheduling requirements.

The result is greater operational security, clearly structured system architecture and maximum transparency – a future-ready automation solution designed to meet the highest industry standards.

This successful migration demonstrates the importance of deep process expertise, precise planning and close collaboration in sensitive production environments.

Mariusz Ziombek, Managing director, SCHULZ Infoprod Poland

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Bartosz Balcerzak

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30 kilometres of cabling for smart design

Building services engineering at GRIMME

Clean lines, well-conceived spatial concepts and a strong commitment to design excellence:

At the headquarters of the GRIMME Group in Damme, a modern office building is currently taking shape, combining architecture and interior design in a contemporary way. Intelligent design requires equally intelligent technology – making this the perfect project for our integrated building services expertise.

The new building, including a sophisticated connecting bridge, has been seamlessly integrated with the existing structure and features high-quality solutions down to the smallest detail. “This is a highly sophisticated, future-ready office building – both in terms of its facilities and technical implementation. What we see here is a carefully considered overall concept,” explains our project manager, Dominik Garling.

One of the project’s defining features is the lighting concept. Instead of standard solutions, continuous light lines, targeted accent lighting and individually planned lighting designs shape the overall appearance. Combined with the sophisticated interior architecture, this creates a harmonious balance between functionality and atmosphere. Describing the scale of the project, Dominik Garling explains: “To make this possible, our teams installed around 30 kilometres of network cabling and approximately 1,300 connection points – creating an infrastructure that meets the demands of modern working environments.” The entire system is controlled via KNX bus technology for intelligent building automation. This allows lighting to be managed according to demand and supports sustainability, for example through sensors that automatically switch off lighting when it is no longer required.

Particular attention was paid to integrating the technology into the architectural concept. Traditional wall-mounted power sockets were deliberately avoided. Instead, cables, connections and sockets are discreetly routed through the floor and concealed beneath a narrow brush channel. From there, cables can be guided directly to individual workstations.

In addition to the lighting and network infrastructure, we also upgraded and expanded the transformer technology to provide a more powerful and reliable energy supply for both the new building and the existing facility. The project forms part of the GRIMME Group’s extensive investment programme across its sites. For us, it is an excellent example of how modern building technology is implemented today: intelligently connected, seamlessly integrated into the architecture, and driven by a clear commitment to quality, functionality and design.

The best building technology often goes unnoticed. It works in the background, supports everyday use and at the same time becomes an integral part of the overall architectural concept.

Dominik Garling, Project manager, building automation

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Teresa Bührmann

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Der Beitrag 30 kilometres of cabling for smart design erschien zuerst auf SCHULZ Systemtechnik.

Energy infrastructure for OPTICUM

Power supply for a research facility

A new state-of-the-art research building for optical technologies is currently being developed on the Leibniz University campus in Hannover-Marienwerder. Covering a total area of around 8,000 m², OPTICUM will provide a collaborative environment where approximately 120 researchers from different disciplines will work together on the precision optics of the future.

Large-scale equipment, test halls, laboratories, as well as sensitive precision and measurement systems place particularly demanding requirements on the power supply infrastructure. “This was far from a standard building installation project. The power supply and distribution systems required a significantly higher level of technical expertise,” explains Christian Liebelt, commercial manager of SCHULZ Hamburg. By installing the transformer substation, a standby power system and a medium-voltage switchgear system from a leading manufacturer, we created the foundation for reliable, high-performance operation.

OPTICUM brings together expertise from physics, mechanical engineering, electrical engineering, computer science, mathematics and chemistry. With our energy infrastructure, we help ensure that this interdisciplinary collaboration can take place under optimal conditions – reliable, powerful and future-ready.

Whether in laboratories, test halls or precision engineering environments, a reliable power supply is essential for enabling research to realise its full potential.

Christian Liebelt, Commercial manager, SCHULZ Hamburg

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Hygiene drives the industry

Conveyor technology in the food industry

Whether in frozen food environments, logistics centres or production facilities, the food industry is subject to particularly stringent hygiene requirements.

These requirements are also a key focus when our conveyor technology teams develop new automation solutions. Hairnets, protective clothing, handwashing procedures and insulated jackets in chilled environments are all part of the daily routine for our colleague Raffael Berssen, conveyor technology specialist. “You get used to it very quickly,” he says. As project lead, he was involved in three projects delivered together with Helmers Intralogistic Systems.

For an international food manufacturer in Dubai, we are expanding an existing production line. The electrical engineering design and software programming are provided by SCHULZ, while installation is carried out by a local team. At the same time, we delivered the conveyor technology for empty and filled crates at a food wholesale and foodservice facility in Gallin, northern Germany. In addition to planning and control panel manufacturing, the project also included installation works. For a third project involving the construction of a major cold storage and logistics centre in Bückeburg, we supplied the complete conveyor system, including programming and commissioning.

All three projects shared the same demanding requirements for hygiene, materials and engineering design. Acid-resistant and easy-to-clean components must withstand intensive high-pressure cleaning without compromise. “Every element must be capable of being cleaned thoroughly and comply with strict hygiene standards,” explains Raffael Berssen. This makes comprehensive quality assurance all the more important. That is where SCHULZ ProKom comes into play. The documentation tool enables every detail to be recorded, documented and tracked transparently by all project stakeholders. Building on the successful partnership with Helmers, further projects are already underway, using intelligent conveyor technology to optimise processes and support long-term operational reliability.

In the food industry, technology, hygiene and documentation must work together seamlessly. With SCHULZ ProKom, every step remains transparent and fully traceable.

Raffael Berssen, Conveyor technology specialist

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Power on the move

Grid buffer for external power supply in vehicle final assembly

In modern automotive manufacturing, a continuous power supply is essential for ensuring process reliability and product quality. This is exactly where our external power supply solution comes into play, developed specifically for a major automotive manufacturer. The intelligent battery system with integrated inverter is built directly into a skid platform used in the vehicle final assembly process.

The challenge: during certain conveyor sections, the platform is temporarily disconnected from the power rail. At the same time, vehicle bodies still require power for processes such as software updates, system testing and ECU flashing. Our solution bridges this gap and ensures a stable, uninterrupted power supply – compactly integrated and precisely adapted to the limited installation space available.

This allows vehicle systems to be fully tested even when disconnected from the regular power supply. At the same time, operating and diagnostic data remain continuously available.

The solution was initially deployed successfully at a production site in Germany before being further optimised for use in additional plants. At its core is an ultra-flat lithium-ion battery system with integrated battery management. A carefully designed control architecture ensures high reliability and ease of maintenance.

A continuous power supply and uninterrupted access to diagnostic data are essential for reliable production processes. That is exactly what our grid buffer provides – even beyond the power rail.

Axel Schumacher, Technical sales, SCHULZ Systemtechnik Bremen

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Der Beitrag Power on the move erschien zuerst auf SCHULZ Systemtechnik.

Batch traceability to go

SCHULZ 𝘱𝘳𝘰𝘥𝘶𝘤𝘵𝘪𝘰𝘯𝙨𝙩𝙖𝙧®: new web-based module

To provide greater transparency in batch traceability, we have expanded SCHULZ productionstar® with a new web-based module. It runs directly in any web browser on any device – with no complex installation required.

The modern and intuitive user interface displays all relevant information at a glance. Customer-specific data fields are automatically recognised and displayed. Flexible filtering options for every column, combined with a comprehensive full-text search, make it easy to find batches, production orders or materials quickly – even within large datasets.

A particular highlight is the integrated Sankey diagram. It visualises material flows and proportional quantities in a clear graphical format. This makes it immediately visible which raw materials have been incorporated into which products – from their origin right through to the finished product. The result is a significant advantage during product recalls and quality investigations, where transparency and rapid response are essential.

The best software solutions are those that make complex information available simply and quickly.

Daniel Magin, Head of software development, SCHULZ Systemtechnik

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Janina Bauken

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Production system for hybrid components in electric vehicle manufacturing

Automation solution for outsert technology

In modern electric drivetrains, highly complex components are responsible for battery management and power distribution. These often consist of delicate individual parts whose assembly in high-volume production requires exceptional precision. Outsert moulding offers a practical solution by transforming these components into hybrid parts.

TB&C GmbH (a Delta Group company) specialises in exactly this type of component. Using outsert technology, metal structures are overmoulded with plastic to create functional hybrid components. These parts are easier and faster to install, offer a high level of functional integration, reduce weight and help lower manufacturing costs. As a supplier to the automotive industry, TB&C provides these components to manufacturers including BMW for the production of its latest electric vehicle models.

To make the assembly of these hybrid components even more efficient, TB&C commissioned our special-purpose machinery team to develop a dedicated automation solution. The objective was to create a highly automated production system for outsert moulding that intelligently links multiple process steps.

The system includes the automated feeding of coated copper busbars into the injection moulding machine, unloading of overmoulded components and subsequent manufacturing processes such as punching, bending, calibration and riveting. Camera-based quality inspection, high-voltage testing, DMC marking, cleaning and automated tray packaging are also fully integrated into the process.

Alongside an innovative technology for lifting and transporting multiple small components simultaneously, precise project planning was essential. To enable production to start as quickly as possible, the system was implemented in three development stages.

Bernd Mühl, sales manager for special-purpose machinery at SCHULZ, explains: “The production line had to be operational within a very short timeframe while still allowing room for additional process steps in the future. This modular approach was a key success factor both in the system design and in securing the project.”

TB&C particularly valued the collaborative partnership throughout the project: “The intelligently designed and highly practical automation solution delivered by the SCHULZ team, combined with an exceptionally fast implementation, impressed us from the outset. We look forward to continuing our partnership on this project and on many future initiatives,” says Daniel Stadelmann, process engineer and project manager at TB&C. “Particularly in complex manufacturing environments like this, it is essential to work with a reliable partner who understands the technology, production processes and the requirements of leading automotive manufacturers equally well.”

Für dieses Projekt sowie für zahlreiche weitere Vorhaben ist eine weiterhin partnerschaftliche Zusammenarbeit vorgesehen und erwünscht“, berichtet Daniel Stadelmann, Process Engineer und Projektverantwortlicher von TB&C. „Gerade bei solch komplexen Fertigungsprozessen ist ein zuverlässiger Partner wichtig, der Technik, Prozessabläufe und Anforderungen der Markenhersteller im Automotive-Bereich gleichermaßen versteht.“

With this solution, our special-purpose machinery team has once again demonstrated how intelligent automation can help drive the future of electric mobility.

Particularly in complex manufacturing environments like this, it is essential to work with a reliable partner who understands the technology, production processes and the requirements of leading automotive manufacturers equally well.

Daniel Stadelmann, Process Engineer TB&C GmbH

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Bernd Mühl

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Der Beitrag Automation solution for outsert technology erschien zuerst auf SCHULZ Systemtechnik.