Keller Feinwerktechnik GmbH

Special machine construction

In special-purpose machine construction, machines and systems are created that are precisely tailored to your specific requirements. This is where standard solutions reach their limits. Whether it's new product variants, higher cycle rates, stricter quality requirements, or limited installation space: if processes need to run economically, reliably, and reproducibly, you often need customized machines that integrate seamlessly into your production.

The added value is obvious: You receive a solution that measurably improves your processes through automation, consistent quality, and a production process tailored to your specific requirements. As a partner in special-purpose machine construction, Keller Feinwerktechnik supports you from the initial concept to the fully operational system, providing technical expertise, clear project structures, and a focus on long-term operational reliability.

What companies can expect from special machine construction

Technical decision-makers and purchasing managers typically share the same goals: faster processes, lower unit costs, less scrap, and a system that runs reliably. This is precisely where Keller Feinwerktechnik comes in, with solutions that aren't just "approximately right," but demonstrably effective.

Typical starting situations include, for example:

Manual work steps should be automated to relieve staff and avoid bottlenecks.
Quality checks must be fully documented and secured in accordance with standards.
Product changes and product variety require flexible, easily reconfigurable systems.
Space constraints, cycle time, or safety requirements cause standard machines to fail.

Our approach: We develop special-purpose machines and industrial automation solutions that translate precisely these requirements into robust, economical technology, with clearly defined interfaces, reproducible results and an operating concept that is convincing in practice.

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Services in plant engineering:
from idea to commissioning

As a supplier of custom-built machinery, we deliver not just individual components, but a complete, integrated solution. This reduces coordination efforts, minimizes project risks, and ensures a smoothly documented transition into your daily production.

Development & Concept

It all starts with understanding your task: product, process, environment, quality criteria, and target costs. From this, we develop a robust concept, including a feasibility study, safety considerations, and clear specifications. This creates a reliable foundation for adherence to deadlines and budgets.

Design & Engineering

In the design process, we combine mechanics, electronics, and software into a functioning unit. This includes, among other things:

mechanical design and layout
Sensor and drive concepts
Control technology and user interfaces
Interfaces to peripherals, IT and existing lines

Especially in special machine construction, forward-looking engineering is crucial: We plan maintenance access, spare parts strategies and later expansions from the very beginning.

Manufacturing & Assembly

In manufacturing, we rely on reproducible processes, tested assemblies, and a design that is easy to assemble. This is followed by assembly with functional tests and preliminary acceptance, ensuring that the system is not "running for the first time" at the customer's site, but is already producing reliably at the factory.

Commissioning & Handover

Every detail counts during commissioning: cycle time, process window, usability, safety features, and documentation. We support the ramp- up , train your team, and assist with fine-tuning until the system reliably achieves your target values.

Individual solutions instead of standard machines

Standard machines are economical when tasks and constraints are standardized. In practice, however, processes are often unique: component tolerances, variants, material properties, media availability, cleanliness requirements, or a tight existing layout. Custom machines take precisely these factors into account, thereby creating measurable advantages.

The result is not just a machine, but a solution tailored to your production: scalable, easy to maintain, and designed for high availability. This makes building a custom machine a worthwhile investment, not only in terms of initial purchase but throughout its entire lifecycle.

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Real-world examples: Special-purpose machines that solve problems

Concrete projects from practice show how individual machine concepts can sustainably solve real production problems

The world's first fully automated belt production line

Automated assembly systems for stable cycle times

When manual assembly reaches its limits, fluctuations in quality and output occur. An automated assembly system takes over recurring steps, such as joining, screwing, dosing, or pressing, and monitors process parameters in real time.

Benefits: constant cycle times, lower error rate, higher process reliability and transparent traceability.

Testing and measuring machines for quality assurance and documentation

In many industries, inspection certificates are mandatory, but the inspection process shouldn't slow things down. Testing and measuring machines integrate sensors, camera systems, or force-displacement monitoring directly into the workflow. Deviations are detected immediately, results are documented, and, if necessary, the affected parts are automatically rejected.

Benefits: less waste, clear proof of quality, standards-compliant documentation and quick response to process drift.

Test cell for measuring customer components

Packaging and handling systems for smooth material flows

Bottlenecks often arise not in the core process, but in handling: feeding, singulation, buffering, labeling, or packaging. Customized handling systems in special-purpose machine construction ensure material flow, even with delicate parts, different formats, or a high degree of product variety.

Benefits: fewer downtimes, stable line performance, ergonomic relief and a clean handover to logistics or shipping.

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Benefits for your company

Efficiency improvement

Automation and optimized processes reduce cycle times, manual tasks, and rework. This increases overall equipment effectiveness and makes capacity planning more predictable.

Quality assurance

Integrated testing concepts reduce variation and scrap. Measurement and process data create transparency, enabling internal improvements and fulfilling external verification requirements.

Competitive advantages

Those who produce faster, more reliably and cost-effectively can shorten delivery times, manage product variants economically and bring new products into series production more quickly.

Future security

Modular design, expandability and service-friendly construction ensure that your system grows with you, whether you need new products, higher production volumes or additional quality requirements.

Our references at a glance

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Request a free consultation now – we'll provide you with practical advice.

Are you planning a new plant or would you like to automate an existing process? Whether it's special-purpose machinery, plant engineering, or targeted automation solutions: We develop a solution that fits your requirements, interfaces, and target values – transparently, structurally, and with a clear focus on cost-effectiveness.

Use the contact form for a non-binding inquiry. Briefly describe your task, and we will get back to you promptly to discuss how we can sustainably improve your production with a customized machine.

Kai Marquardt

Special Machine Construction

+49 4121/7807-427

marquardt.k@keller-feinwerktechnik.de

Thomas Tepp

Contract Manufacturing

+49 4121/7807-430

tepp.t@keller-feinwerktechnik.de

Your questions answered quickly

Here you will find answers to the most important questions.

What is meant by special machine construction?

Special-purpose machine construction encompasses the development and building of machines or systems precisely tailored to a specific customer requirement. It is typically employed when standard machines cannot reliably meet the required function, cycle time, accuracy, or process reliability. Crucially, this involves the precise translation of process requirements into a technically robust machine concept.

How does a special machine construction project typically proceed?

A typical process involves clarifying requirements (specifications/statements of work), a concept phase, design, manufacturing/assembly, and subsequent commissioning with acceptance testing. During the concept and design phases, interfaces (mechanical, electrical, software), safety functions, and cycle time/quality targets are defined. Before final acceptance testing, functions, process capabilities, and relevant safety requirements are verified against defined criteria.

What information should we provide for a reliable inquiry?

Helpful information includes product data (drawings, tolerances, material), process descriptions (sequence, cycle time, variants, batch sizes), and quality requirements (inspection characteristics, inspection methods, traceability). Additionally, boundary conditions are important: available media, space constraints, IT/interfaces (e.g., MES/ERP), company standards, and safety regulations. The clearer these points are, the faster technical risks, effort, and costs can be realistically assessed.

What factors influence the cost and delivery time of a custom-built machine?

Costs and delivery times primarily result from complexity (number of stations/axes, sensors, software scope), required accuracy, and the validation/testing effort. Product variety, component handling, necessary safety measures, and documentation and standards requirements (e.g., CE conformity) also influence the scope. Often, the effort is most easily influenced in the early concept phase, as this is when the fundamental architectural decisions are made.

How is it ensured that the machine achieves the required quality and process reliability?

Typical features include defined acceptance criteria and structured tests, such as functional tests, repeatability/process capability, and fault and safety tests. A risk-oriented design (e.g., FMEA/failure analysis) helps to safeguard critical process steps early on. Additionally, documented settings, recipes, and clear maintenance/calibration concepts ensure that performance remains consistently reproducible in series production.

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