Retrofit
Upgrade your Production.
Modernize existing glass production with WALTEC’s ESERVO retrofit solutions. Replacing conventional hydraulic and pneumatic systems with precisely controlled servo technology reduces energy and compressed-air consumption while improving process accuracy, repeatability and production efficiency.
From pressing cylinders and main closers to plunger rings, press supports, pushers and kick-outs, each component is tailored to the machine and its operating requirements.
Designed for WALTEC equipment and machines from other manufacturers, these upgrades help reduce maintenance, improve working conditions and extend equipment life. Proven machinery meets advanced technology for a more efficient future.
ESERVO COMPONENTS
Upgrade your production.
Improve your efficiency.
Modernize your existing glass production line with WALTEC ESERVO performance components. Replacing conventional hydraulic and pneumatic systems with precisely controlled servo technology reduces energy demand, improves repeatability and helps extend the productive life of your equipment.
ESERVO components deliver process power when it is needed. Controlled movements support higher production efficiency while reducing compressed air consumption and oil-related contamination in the working environment.
Designed for retrofitting, the range supports upgrades to WALTEC presses and equipment from other manufacturers. Each solution is matched to the existing machine configuration and the requirements of your production process.
Figures indicate potential improvements across different ESERVO retrofit configurations. Actual savings and output gains depend on the existing equipment, operating conditions and scope of the upgrade. The values are not additive and may not be achieved simultaneously. WALTEC evaluates the potential for your specific installation.
ESERVO COMPONENTS
Improved sustainability – significant energy savings
WALTEC's latest generation of ESERVO performance components enables the replacement and upgrade of older machinery. Replacing inefficient conventional hydraulic or pneumatic systems allows for significant savings in electrical energy and compressed air. At the same time, servo technology improves operator health and safety by reducing oil contamination and residues in the air during operation.
WALTEC uses gearless, electric direct drives for innovative glass machines with great success. Since 2010 all tables of our high-performance press machines have been driven with state-of-the-art electric torque direct drives. This torque motor recovers energy during deceleration and returns it into the system.
We offer the following components in the ESERVO-series:
1ESERVO Direct Drive
- High torques: up to 70,000 Nm
- Short table indexing times: up to 0.25 seconds
- Smooth movement: free from backlash and jolts
- Online drive supervision and low maintenance
2ESERVO Pressing Cylinder
- Less energy consumption: reduce energy costs by up to 85% compared to conventional hydraulics
- Lower emissions (operator health) and less danger (fire): no oil reservoir next to the machine is required and improved safety due to less oil in the air
- Heavy-duty performance: pressing force up to 20 tons
- Extended lifetime: including proprietary technology
- Memory function
3ESERVO Funnel
- Less energy consumption by saving compressed air
- Adjustable vertical stroke length via control panel
- Memory function
4ESERVO Main Closer
- Reduce press cycle time by up to 100 ms
- Less compressed air: save up to 80 m³/h
- Extended mould lifetime: controlled and smooth movement
- Memory function
5ESERVO Press Support
- Less energy consumption by saving compressed air
- Memory function
6ESERVO Kick-Out
- Less energy consumption by saving compressed air
- Adjustable vertical stroke length via control panel
- Memory function
Eservo Pressing Cylinder
Powerful pressing.
Precisely controlled.
Upgrade conventional pressing technology with an electrically driven solution that combines high pressing force with accurate, repeatable movement.
The ESERVO Pressing Cylinder uses WALTEC’s proprietary drive technology and is available for press forces up to 20 t. Precise control supports consistent forming conditions and reproducible production results.
By replacing a proportional hydraulic or pneumatic cylinder, significant energy savings can be achieved. Eliminating oil reservoirs next to the press improves operator health and reduces the risk of fire in the production area. The robust drive design supports a longer service life and reduces maintenance requirements.
Engineered for demanding production
Eservo Main Closer
Faster closing.
Smoother production.
Upgrade mould closing and locking with controlled servo movement for split-mould production.
The ESERVO Main Closer replaces a conventional pneumatic closing mechanism with a powerful servo motor and connecting-rod system. Precisely controlled motion allows the mould to close smoothly and repeatably while reducing the compressed air required for this operation.
Gentle closing and locking reduce wear on mould edges and help extend mould life. Shorter closing movements can also release valuable time within the press cycle.
Controlled motion. Lasting benefits.
Eservo Plunger Ring
Prescise ring movement.
Perfectly synchronized.
Upgrade the plunger ring movement with a precisely controlled electric servo drive for accurate and repeatable glass forming.
The ESERVO Plunger Ring provides an independently controlled vertical movement of the ring in combination with the ESERVO Pressing Cylinder. The positions of both servo axes are continuously coordinated, enabling precise control of the interaction between plunger and ring throughout the forming process.
Defined position limits maintain the required minimum distance between both axes and help prevent collisions. This synchronized control provides a reliable basis for repeatable forming conditions while offering the flexibility to precisely adjust the movement to the article and process requirements.
Precise control for demanding forming processes
Eservo Press Support
Stable support.
Efficient pressing.
As part of the structural press machine framework, WALTEC’s ESERVO press support serves a vital stabilizing role that generates counter-pressure while mechanical pressure is applied to the machine during the pressing process.
It also reduces energy costs by replacing the costly compressed-air-driven pneumatic press support systems. The adjustable vertical stroke length and speed adjustments via control panel as well as the memory function (“recipes”) round out the functionality of this unit.
Eservo Pusher
Gentle transfer.
Consistent quality.
Improve the final transfer into the annealing lehr with precisely controlled servo movements.
The ESERVO Pusher uses two independently controlled servo motors: one for horizontal movement and one for vertical movement. This allows the transfer sequence to be adjusted smoothly and repeatably.
Variable speed control and a soft-touch function reduce abrupt contact with the glass articles. The result is gentler handling, fewer scratches and less product damage during loading into the annealing lehr.
Replacing the pneumatic pusher drive also reduces compressed air consumption and removes the maintenance associated with its pneumatic control valves.
Precision that protects your products
Eservo Kick-Out
Easy adjustement.
Faster ramp-up.
One of the latest WALTEC developments is the ESERVO Kick-Out used in WALTEC’s automated production lines.
Replacing the standard pneumatic design, it is designed for simple and effective operation.
Simple adjustment of the vertical stroke length needed for all the different items produced on a line provides additional flexibility when changing between different articles.
The memory function enabling a much faster ramp-up time when an item is being produced again in the future is an additional benefit.
The system also saves energy by eliminating compressed-air consumption in this area.
Contact
Talk to our experts.
If you have questions about a production line, an upgrade or ongoing service, our team is here to help. Get in touch to discuss your requirements and next steps.