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Sustainable factory overhaul at KILIA: Increase efficiency, save resources

  • Kilia
  • Sep 3
  • 3 min read

Sustainable. Precise. Made in Germany.


The best machine is the one that produces reliably day after day. That is precisely why we at kilia.de (HELTEK Maschinenbau) specializes in a genuine factory overhaul – not a "cosmetic tuning," but a technically sound, complete restoration with measurable improvements. Whether it's a Kilia Bowl Cutter (30 L, 50 L, 65 L, 125 L, 325 L, vacuum/vacuum cook) or an angle grinder (e.g., G160 2000 S ): We bring your machine up to date – for greater efficiency, hygiene, and safety.



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What does “factory reconditioned” mean at KILIA?


In short: completely disassembled, professionally reconditioned, technically modernized, documented and tested – with manufacturer’s guarantee .

In detail this means:


  • Complete disassembly down to the base frame, cleaning and visual inspection of all components

  • Stainless steel processing (removal of deposits, sandblasting/polishing, edge processing)

  • Surface treatment (non-product contact): Powder coating of base frames/cladding and steel components – robust, easy-to-clean surface; coloring according to customer specifications.

  • Measurement & tolerance testing of safety and product-relevant components

  • Renewal of bearings, seals, cables, sensors and safety-relevant assemblies

  • State-of-the-art drives/electrics (frequency converters, efficient motors, modern PLC/HMI)

  • Assembly according to torque and quality plan , final functional test (FAT) including test report

The result: consistent product quality, fewer downtimes, lower energy costs – and all this with maximum spare parts availability.



The KILIA process in 10 steps


  1. Initial inspection & findings – visual inspection, running noise, play/impact, leaks, safety functions

  2. Complete disassembly – knife shaft, bowl, plate drive, hydraulics, vacuum, electrics

  3. Cleaning & surface treatment – blasting/polishing of stainless steel surfaces, mating surface preparation

  4. Measurement & documentation – shafts, bearing and seal seats, geometry, surface roughness; preparation of a measurement/condition report

  5. OEM-quality spare parts – including blade shafts, bearings/seals, blade bolts, cutting sets , and wiring harnesses

  6. Drive & Electrics – energy-efficient motors, frequency converters (precise speeds), PLC/HMI update

  7. Hydraulics & Vacuum – Unit overhauled/new, cylinder overhauled/new; vacuum pump tested, leak test

  8. Stainless steel processing – hygienic surfaces, edge deburring; surface finish according to specifications on request

  9. Assembly & adjustment – defined torques, alignment, gap and concentricity testing

  10. FAT & Acceptance – Vibration/Temperature/Leakage measured, Safety check , Handover with documentation


Optional upgrades & retrofits


  • Frequency converter package : precise knife and bowl speeds, recipe repeatability, energy savings

  • New PLC/HMI (e.g. multilingual DE/EN/ other languages), recipe management, batch protocol

  • Noise reduction through optimized vacuum system and soundproofing measures

  • Safety retrofits : emergency stop, protective devices, leak protection preparation

  • Data logging : process data for QA, traceability, audit

  • ADS systems for wolves: automatic sealing/lubrication system for longer service life


Quality, safety & guarantee


  • Factory reports : disassembly, measurement, assembly and FAT reports

  • Safety functions tested

  • Spare parts : long-term availability – fast from Germany

  • Warranty : 6 months manufacturer's warranty on factory reconditioned machines

Your machine leaves our factory plug-and-produce – including documentation and training.

Sustainability & Economic Efficiency


Why overhaul instead of buying new?


  • Extend service life: The stainless steel body and base frame are retained, only wearing parts are replaced.

  • Save resources: significantly less primary raw materials and waste compared to new production.

  • Reduce energy: modern, controlled drives (frequency converters) and optimized mechanics reduce power consumption during operation.

  • Regional supply chains: Manufacturing, overhaul, and spare parts from Germany – short distances, high availability.

  • Less downtime: longer downtimes and planned maintenance reduce the total cost of ownership (TCO) .


Measurably sustainable (on request) We create a project-specific resource and CO₂ balance : reuse rate, estimated kWh savings per year, and expected emission reductions – transparently documented in your acceptance documents.

Take-back & upgrade capability Modular design, long spare parts availability and documented retrofits (e.g. HMI upgrade, data logging) make your machine repairable and future-proof .

Packaging & Shipping Reusable packaging, single-use materials, and optimized logistics – for less waste and lower transport emissions.

Factory refurbished = saves resources. Good for your budget and the environment.

Frequently Asked Questions (FAQ)


How long does a factory overhaul take?

This depends on the machine type and the desired upgrade scope. Typically, it takes a few weeks.

Will I receive a test report?

Yes. You will receive measurement, assembly, and FAT reports.

Are customer-specific customizations possible?

Yes – from HMI language/layouts to additional sensors and special surface requirements.

Is there a guarantee?

Yes, we offer a 6-month manufacturer's warranty on factory-refurbished machines.


Next step

Are you considering having your KILIA machine factory overhauled or are you looking for a factory-refurbished KILIA machine ? Contact us – we will advise you, assess your machine, and provide you with a binding quote including a timeframe and cost estimate.

Contact: via the contact form on kilia.de or directly by phone/email.


 
 
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