What does a factory overhaul mean at HELTEK-KILIA?
A factory overhaul at HELTEK | KILIA is far more than a typical repair or refurbishment of a used machine. Our goal is to restore a KILIA cutter, both technically and visually, to a condition that is consistently aligned with the standards of a new machine .
For this process, the machine is not only inspected and repaired in certain areas. It is completely disassembled, rebuilt from the ground up, and equipped with numerous new or completely overhauled components.
The result is a KILIA cutter designed for many more years of demanding production.
Completely disassembled – except for the machine frame
Every factory overhaul begins with complete disassembly.
The cutter is disassembled down to its basic frame. Motors, drives, cutter shaft, disc drive, electrical system, hydraulics, fairings, bearings and all other components are removed.
This allows us to work not only on the visible areas of the machine, but especially on those areas that are not accessible during normal machine operation.
Only this consistent rebuild distinguishes a true factory overhaul at the manufacturer from a simple repair or partial refurbishment.
A new basis for a second machine life
A particularly important part of the factory overhaul is the base plate.
The machine receives a completely new base plate . This is professionally welded in and then elaborately refurbished together with the base frame.
Steel components inside the machine are blasted to completely remove old coatings, corrosion, and contaminants. Other stainless steel components are glass bead blasted and refinished accordingly.
The base frame then receives a high-quality, durable powder coating with an appropriate layer thickness .
This creates an extremely robust surface that is designed to withstand the demanding conditions in the food industry, particularly those involving moisture and intensive cleaning.
The machine is thus literally getting a new foundation.
Rebuilding piece by piece
Once the surface work is completed, the actual reconstruction begins.
Our specialists will reassemble the machine step by step. This doesn't simply involve removing the old components. Numerous mechanical, electrical, and hydraulic parts will be replaced with new or completely refurbished components.
Our aim is:
No compromises on the central components.
New central lubrication system and modern engine design
A new central lubrication system, built to the latest technical standards, will be installed on the new base plate.
Another important detail is our modern motor tensioning rocker. It ensures optimal and consistently reproducible belt tension.
The motor clamping rocker is made of stainless steel . This means the main motor is not mounted directly on the base plate, but rather at a higher elevation.
This offers a crucial advantage: water cannot collect directly under or on the motor housing. Especially in machines that undergo regular, intensive cleaning, this design significantly contributes to the protection and lifespan of the drive system.
Siemens main motors
We also rely on high-quality components for the main drive.
Depending on the machine configuration, the following may be included, among others:
brand new Siemens motors of the current PH8 series or
Completely overhauled Siemens motors from the proven Siemens PH7 series
for use.
This ensures that the high-performance and reliable character of a KILIA cutter is retained even after factory overhaul.
New platter drive and completely new platter shaft bearings
Only new drives or gearboxes are used in the plate drive.
The plate shaft bearing is also completely renewed.
This includes, among other things:
Storage,
Wave,
bearing seats and
all relevant storage components
renewed or professionally refurbished.
Only then is the cutter bowl plate reassembled and precisely aligned.
This means that a central mechanical assembly of the cutter will be practically rebuilt from scratch.
Wear parts made of modern blue POM
All relevant wear components are also replaced.
These include, for example:
Scraper,
Guided tours,
Rings,
Sliding and wear elements.
Here we use modern components made of blue food-grade POM , as are also used in current machines.
This means that factory-refurbished KILIA cutters simultaneously benefit from technical advancements in modern mechanical engineering.
Cutter shaft without compromise
The cutter shaft is one of the most stressed and safety-relevant components of a cutter.
That's why we're not making any compromises in this area.
As part of our factory overhaul, the essential components of the cutterhead system are renewed. These include, in particular:
Cutter shaft
Cutter shaft bearings
Storage and
Bearing seats.
The cutter shaft system is built and adjusted according to our high standards.
Our aim here is also clear:
High performance – based on the standard of our new machines.
Complete new electrical system
Even during a comprehensive factory overhaul, the electrical equipment is not simply reused.
The entire control and power electronics system is being rebuilt.
This includes, among other things:
Protect,
Relay,
Frequency converter
PLC control,
HMI control panel,
Pipes and cables,
Security technology,
Sensor technology as well as
other electronic components.
This also gives an older KILIA machine a modern control architecture and operation.
The result is not only significantly increased operational reliability, but also a much better supply of spare parts and service capability for the coming years.
New or completely overhauled hydraulics
Hydraulics also play an important role in larger KILIA cutters.
The system is also undergoing a comprehensive overhaul here.
Depending on the machine and model, the following may be included, among other things:
Hydraulic hoses replaced,
Hydraulic power units completely overhauled or replaced,
Hydraulic cylinders overhauled or renewed as well as
Connections and hydraulic components were checked and replaced.
This will also bring this important functional area of the machine up to a reliable technical standard.
At KILIA, factory overhaul means: rebuilding instead of repairing.
A factory overhaul at HELTEK | KILIA therefore does not mean simply refurbishing a used machine and replacing a few defective components.
We are rebuilding the machine from the ground up.
From the new base plate to the cutter shaft and disc bearing, to motors, electrics, control, hydraulics and wear parts, the crucial systems are completely renewed or professionally overhauled.
In this way, a proven KILIA cutter is transformed into a high-performance production machine that achieves almost the same technical and visual standard as a new machine .
In doing so, we combine one of the greatest advantages of older KILIA machines – their extremely robust basic construction – with modern drive, control and automation technology.
Proven KILIA substance. Modern technology. Ready for many more years of production.
This is precisely where the special value of a factory overhaul at the manufacturer lies.
A high-quality existing machine is not replaced, but rather consistently rebuilt and prepared for its next production phase.
HELTEK-KILIA factory overhaul – from proven machine quality, a machine for the future is created.
