As good as new: a production upgrade for baby food

Optimising a control system

At Danone’s Milupa plant in Fulda – renowned for the production of high-quality baby food – our colleagues from Poland have modernised a SCADA system that was more than ten years old. This was far more than a routine update: the automation solution was completely redesigned from the ground up.

The objective was clear: to implement a system that meets today’s operational requirements while fully complying with the strict regulations of the US Food and Drug Administration (FDA).

After developing and evaluating several concepts for different platform providers, the decision was made in favour of Siemens WinCC in combination with PM Logon and WinCC Audit, ensuring full compliance with FDA requirements. Mariusz Ziombek, CEO of SCHULZ Infoprod in Poland, explains the particular challenge involved:

“Data migration was complex, as the legacy system exported project configurations in a specific CSV format, while the new system requires a different structure. By using AI-supported script development, we were able to convert the data very efficiently and significantly reduce manual effort.” The close involvement of Siemens colleagues also proved extremely valuable. From the early concept phase through to the entire project implementation, they provided excellent support and technical expertise.

Thanks to the integration of proven SCHULZ standards across both systems, operators were able to familiarise themselves with the new solution quickly. The project stands as a strong example of our technical expertise – combined with precision and an innovative mindset to meet the highest regulatory standards.

The result: a system that meets current requirements while fully complying with the strict regulations of the US Food and Drug Administration (FDA).

Mariusz Ziombek, CEO, SCHULZ Infoprod, Poland

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Bartosz Balcerzak

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Dock, shut down, recharge

Shore power system for Rendsburg District Harbour

Loud engines and the pungent smell of ship diesel often define the atmosphere in ports. At Rendsburg District Harbour, however, a fresh breeze is now blowing: thanks to a new shore power system, vessels can switch off their engines and draw electricity directly from the grid while alongside. During berthing periods, up to ten inland vessels and two passenger ships can now be supplied with low-emission shore power.

Our team was responsible for delivering the entire energy infrastructure – from the expansion of cable routes and the medium-voltage system through to two transformer substations. Project Manager Jörg Hochhaus recalls the challenges involved:

“Harbour operations continued as normal, so we had to align our work very closely with on-site processes. That required detailed planning and precise coordination of individual work steps as well as the delivery of materials. Thanks to our experience with similar harbour projects, everything ran smoothly.” The modernisation achieved through the new shore power system significantly reduces both emissions and noise, setting new standards for sustainable port operations – and for the region as a whole.

Harbour operations continued throughout the project, so we had to coordinate our work precisely with on-site activities. With clear planning and accurate coordination, everything ran smoothly.

Jörg Hochhaus, Projektleiter SCHULZ Systemtechnik, Hamburg

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Christian Liebelt

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SCHULZ Energy Concept

Innovation means planning for the future

When it comes to our consulting expertise in energy concepts, we take a new approach: instead of offering individual components, we provide our customers with tailored advice that takes current market price developments as well as the applicable legal framework into account.

Til Erasmi, our specialist for energy market consulting, explains: “I look at systems, legislation, electricity prices and grid charges from an economic perspective and make complex energy systems understandable and transparent for the customer.”

The consulting focus is on charging infrastructure and battery storage systems, complemented by photovoltaic installations. Ultimately, however, the service is relevant for all sectors and industries looking to optimise their energy management.

To achieve this, Til Erasmi uses a specialised tool from the company minimum energy, which takes a wide range of parameters into account:

‣ Dynamic, real-time electricity prices 
‣ Grid charges and grid connection points
‣ PV capacity and self-consumption 
‣ Forecasts of future electricity demand (e.g. due to electric HGVs)

“Calculating all these interactions manually is virtually impossible,” says Erasmi. “Only through the algorithms and AI-based optimisations integrated into the tool are we able to generate reliable results.”

The key benefit: it becomes immediately clear which measures make economic sense and how quickly they will pay for themselves. “I present the site as a digital twin, explain the cost structures, and customers instantly understand where and how much they can save.”

The SCHULZ Energy Concept combines expert knowledge, innovative tools and sound economic analysis in a single service – delivering immediate added value and long-term planning certainty. “This is specialist expertise that can’t simply be copied,” Erasmi explains, “and that’s exactly what makes the difference for our customers.”

I analyse systems, legislation, electricity prices and grid charges from an economic perspective and make complex energy systems understandable and transparent for the customer.

Til Erasmi, Energy Consultant / Energy Analyst, SCHULZ Systemtechnik

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Til Erasmi

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Consistent building concept for sustainable production

New hall for Pöppelmann KAPSTO®

Sustainability is not a trend for the Lohner plastics processor Pöppelmann — it is firmly embedded in the company’s strategic goals. The new Production Hall 43 for the KAPSTO® business division marks another important step on this journey. At the heart of the building concept is a state-of-the-art small parts production facility, designed with a strong focus on automation, energy efficiency and modern workplace design.

Planning and implementation were carried out in accordance with the criteria of the German Sustainable Building Council (DGNB). In the DGNB pre-certification process, the Pöppelmann hall has already achieved the highest platinum rating; the final certification is imminent. Just a few weeks ago, the German Energy Agency (dena) awarded the industrial building — officially opened in June 2025 — the Energy Efficiency Award 2025 in the category “Think Big! — Complex energy transition projects.” This category recognises particularly advanced and complex energy efficiency solutions.

To supply the hall with energy, no fossil fuels are used at all. The facility runs entirely on electrical energy, primarily sourced from on-site solar generation and wind power from regional wind farms. Photovoltaic panels on the roof are complemented by additional modules on the south façade. Alongside energy efficiency and high-level automation, contemporary workplace design was a central focus of the building concept.

Working with regional partners has always been part of Pöppelmann’s corporate strategy. This, combined with a long history of cooperation on joint projects, provided the foundation for SCHULZ to be part of this ambitious undertaking. Our services include complete electrical installation — from lighting and network infrastructure to control and automation technology. The bespoke construction of switch cabinets was also carried out in-house.

Project manager Carsten Kremer reflects on the challenges: “This project required truly forward-thinking planning down to the last detail — and we made sure that sustainability was right at the top of our to-do list. The most important factor for a successful project was close collaboration with the Pöppelmann team. Only through genuine hand-in-hand teamwork were we able to integrate every component seamlessly — from power distribution to the final sensor.”

Teamwork with a future

Interview:
Jens Stuckenberg from Pöppelmann

In conversation, Jens Stuckenberg, Head of Building Electrical Technology at Pöppelmann, reflects on the teamwork with SCHULZ.

The new Hall 43 is regarded as one of the most important construction projects in Pöppelmann’s corporate history. What triggered it?
Our production capacities were reaching their limits — and at the same time we wanted to become more sustainable and efficient. The idea was to combine production, storage and logistics under one roof. That’s how the vision of a hall that blends ecological responsibility with technological innovation came about.

How significant was the topic of sustainability during planning?
At Pöppelmann, we have long placed great importance on sustainability at every level of the business. We wanted a facility that saves energy and conserves resources over the long term. That’s why we invested in photovoltaic systems, propane heat pumps, rainwater harvesting and a completely CO₂-neutral energy supply.

What was the basis for selecting partner companies for the project?
Sustainability was key. We wanted partners from the region who could handle a project of this scale, who have short logistics routes and a genuine understanding of innovative construction and resource-efficient solutions with a future. SCHULZ was involved as a partner for electrical and automation engineering.

What was your experience of collaboration with SCHULZ?
We’ve worked together for many years. In a project of this size, trust is crucial — and we had that from the start. The SCHULZ team was flexible, solution-oriented and always on equal terms. Importantly, there was always someone available as a contact person, even in challenging situations that went beyond normal working hours.

What was the highlight for you personally?
Definitely seeing it all come together. A vision became reality — and now, standing in this huge hall, every cable, every piece of equipment and every control system is running with maximum energy efficiency. That’s a proud moment.

What’s next?
Hall 43 is a milestone, but we’re continuing to modernise other facilities step by step. We’ll of course be happy to rely on well-tried partnerships like the one with SCHULZ again. Because when you tackle a project of this scale together as a team, not only does the facility grow — but so does the trust.

Facts & Figures

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Carsten Kremer

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Stacking coffee beans at pace

Retrofit for a robotic loading system

Loading coffee sacks is a real challenge: the coffee beans inside shift unpredictably in every direction, and the individual bags follow no fixed order.

And yet, at a renowned coffee processor, a robot has been stacking them with such precision for over 20 years that the filled sacks are placed almost seamlessly into containers for onward transport. A true one-of-a-kind system and ranked among the top ten applications worldwide – as confirmed by the robot manufacturer itself. To ensure long-term functionality and efficiency, it was time to modernise the installation. A job for SCHULZ – after all, both the original concept and its implementation came from us.

As a specialist in green coffee processing (e.g. decaffeination), the company also manages the logistics of these valuable goods for global transport. Production downtime was therefore not an option.

“The migration was planned and carried out like open-heart surgery,” reports Norbert Melcher, our Sales Specialist for Industrial Automation. “With meticulous preparation, we prefabricated all components, laid cables and assembled control cabinets in advance so that every second could be used efficiently during the conversion.”

Implementing the upgrade while operations continued required precise execution and excellent teamwork. Our team delivered the complete modernisation – from new robot integration and programming of the control and safety architecture through to control cabinets, cabling and fine-tuning of the motion sequences. Thanks to the close collaboration with the coffee specialists and well-established process workflows, we were able to provide this unique installation with a future-proof upgrade.

With meticulous preparation, we prefabricated all components, laid cables and assembled control cabinets in advance so that every second could be used efficiently during the conversion.

Norbert Melcher, Sales Specialist for Industrial Automation

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Norbert Melcher

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Energy hub powered by SCHULZ

Gasunie: a key project for the energy transition

In Achim near Bremen, an energy project of exceptional scale is currently taking shape. Our customer, the Dutch-German gas infrastructure operator Gasunie, is investing in the expansion of an international energy hub for north-west Europe.

On the approximately seven-hectare site, a highly complex infrastructure is being developed that will play a decisive role in the future energy supply of Germany and neighbouring countries. The new, fully electrically operated compressor station is a key project for security of supply and at the same time makes a significant contribution to reducing emissions. “This project is on a completely new scale for us as well,” explains Rainer Darkow, Head of Ex Plants. “More precisely, it is the largest contract in the company’s history.” As a framework contract partner of Gasunie, we have been commissioned with a comprehensive scope of services – ranging from medium- and low-voltage systems and switchgear to control and process control systems, as well as building services, fire protection and cybersecurity.

The extensive cable routes and numerous interfaces make planning the internal construction-site logistics particularly challenging. Ensuring reliable cable installation under winter conditions is especially critical in order to keep to the project schedule. Project Manager Stephan Heuer adds: “Two of the three new compressor units at the site are scheduled to go into operation by the end of December 2026. Precise timing and forward-looking coordination are therefore top priorities.” To achieve this, five departments from three different locations are working together as a strong, integrated team. Our planners and design engineers collaborate closely across disciplines. Perfectly staffed key roles and seamless cooperation demonstrate what can be achieved together. When energy supply for Germany and north-west Europe is controlled from Achim in the future, it will be powered by the full strength of SCHULZ.

The new electrically operated compressor station is regarded as a key project that is driving the energy transition forward.

Rainer Darkow, Head of Ex Plants, SCHULZ Systemtechnik

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Stephan Heuer

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Combining strengths with B&R

New system partnership

For many years, SCHULZ and B&R Industrial Automation have shared a common vision: developing flexible, innovative and efficient automation solutions.

We are now an official system partner – a B&R Value Partner – enabling us to further expand our solution portfolio in industrial automation.

As a global leader in control, motion control and visualisation systems, B&R focuses on modular and scalable solutions. “With B&R, we share the same mindset: developing customised and future-ready solutions,” explains Alex Banf, responsible for Strategic Business Development at SCHULZ in Hockenheim.

This partnership enables faster integration of new technologies into projects and provides access to an even broader range of high-performance automation systems. Areas such as process control systems, machine control and intelligent production networks offer significant potential in this regard.

A particular highlight was the “Passion4 Automation Day” in September – a B&R event where our colleague Stefan Hitz had the opportunity to present SCHULZ expertise to a large professional audience. Together with Alex Banf, he showcased our capabilities in system integration and machine control and strengthened valuable connections within the system partner network.

“Our collaboration works like an extended workbench in both directions,” reports Banf. “We complement each other perfectly and work together as equal partners.” For our customers, this means greater flexibility, enhanced performance and even more intelligent automation solutions.

Our collaboration works like an extended workbench in both directions – we complement each other perfectly and work together as equal partners.

Alex Banf, Strategic Business Development, SCHULZ Hockenheim

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Alex Banf

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Switching to a cleaner future

SF₆ ban from 1 January 2026

From 1 January 2026, newly installed medium-voltage switchgear containing sulphur hexafluoride (SF₆) may no longer be placed into operation. This has been stipulated in the current EU F-Gas Regulation (EU) 2024/573. The regulation applies to all installations that have previously relied on SF₆ as an insulating medium – a gas with a global warming potential more than 23,000 times higher than CO₂. The EU ban aims to reduce emissions of high-global-warming-potential gases such as SF₆ by two thirds by 2030 compared to 2014 levels.

While existing installations may continue to operate, any new projects from the beginning of 2026 onwards must use SF₆-free technologies. Exceptions apply only to systems ordered before 11 March 2024 or those serving as contingency reserves.

At SCHULZ, we have been supporting our customers in transitioning to future-proof alternatives since the regulation was first announced two years ago – for example, to solutions using purified air as the insulating medium. This technology enables compact design, meets the highest safety standards, and is fully environmentally friendly and low-maintenance.

Our conclusion: SF₆-free solutions are no longer a vision of the future – from 2026 onwards, they will be the sustainable standard.

With SF₆-free alternatives, medium-voltage systems can already be implemented safely, compactly and with minimal maintenance – fully compliant from 2026.

Hans-Georg Hörnschemeyer, Head of Energy Technology, SCHULZ Systemtechnik Wallenhorst

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Hans Georg Hörnschemeyer

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Usability optimisation pays off

User-friendliness becomes a success factor

With every new control system, robotic solution and Human Machine Interface (HMI), expectations regarding user-friendliness – or usability – continue to rise. Wherever machines, software and people interact, the design of the interface determines efficiency and safety.

The growing demand for smart solutions resembling tools from the consumer market shows that simple, intuitive operation, clear user interfaces and reliable functionality are essential. Systems that are easy to operate reduce training effort, prevent operating errors and increase plant availability.

This makes good usability a genuine success factor:

• shorter onboarding times and reduced training requirements,
• fewer operating errors, accidents and downtime,
• higher process quality and occupational safety,
• greater employee acceptance,
• faster implementation of digital systems.

As industrial digitalisation advances, people are once again moving to the centre of system design. Networked plants, self-learning systems and remote control technologies can only realise their full potential when they are clearly structured and easy to operate.

New approaches from the gaming world provide valuable inspiration: colour-guided operating concepts, dynamic icons or adaptive displays that respond to user behaviour – all of which enhance efficiency and safety in production processes.

At SCHULZ, we support companies in approaching usability holistically – from the initial concept phase and HMI design through to integration into existing systems. Our end-to-end operating concepts range from MES (Manufacturing Execution Systems) and SCADA systems down to field level.

The objective: technology that not only works, but inspires. Because every successful automation solution begins where people intuitively understand it.

Good usability is not just a design issue – it is a productivity driver: fewer errors, less downtime and greater acceptance.

Stefan Hitz, Authorised Officer and Head of Process Industry, SCHULZ Systemtechnik

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Stefanie Barjenbruch

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First come, first milled – at SCHULZ!

New flaking line for Bauck Mill

The demand for gluten-free organic products is growing – and Bauck GmbH is ready to meet it.

The expansion with a completely new flaking line for the modern gluten-free mill in Rosche became a SCHULZ project – including planning, installation and commissioning.

The main challenges? Integrating the system into ongoing operations and managing a tight schedule.

Our on-site team was supported by colleagues from Poland. From the initial offer to commissioning, it took just six months.

The new flaking line complements the existing system, which was already a successful SCHULZ project that significantly increased annual capacity to 20,000 tonnes of grain. The company’s overall goal is to double production in the coming years. State-of-the-art technologies for sorting, cleaning, milling and flaking ensure consistently high product quality.

At the same time, this strengthens organic farming in Germany and the region by processing more raw materials in organic and Demeter quality.

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Viktor Hertfelder

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