HMI REPLACEMENT FOR KARLMAYER REBEAMER MACHINE

How We Saved 90% Cost for Tayyab Traders...

The Challenge:

Tayyab Traders faced a major production crisis due to a failed B&R HMI on their KARLMAYER REBEAMER machine.

🚨 The Impact:

• OEM replacement cost a staggering 2 million with no warranty!

• Machine downtime led to significant production losses.

• Urgent need for a cost-effective and reliable solution.

💡 Goal: Find a budget-friendly, efficient HMI replacement without compromising performance.

Our Smart Solution: A Better, More Affordable HMI

Instead of going for an overpriced OEM replacement, we designed a custom Windows-based all-in-one touch PC HMI with tailored software.

✅ 90% cost savings compared to the original OEM HMI.
✅ Faster, smoother touchscreen for improved operation.
✅ Free software backup to prevent future losses.
✅ 1-year warranty on original hardware + 2-month warranty on refurbished hardware, OEM offered none!

How We Did It??

🚀 Step 1: Site Visit & Consultation

• Evaluated the failure and assessed client needs.

• Presented two options: new hardware or a more affordable refurbished solution.

• Client chose the budget-friendly refurbished option.

🔧 Step 2: Hardware & Software Upgrade

• Removed the faulty B&R HMI.

• Installed a Windows-based touch PC with customized software.

• Ensured seamless machine integration.

🛠 Step 3: Testing & Warranty Benefits

• Provided a full backup copy of the software.

• Delivered a 2-month checking warranty for peace of mind.

The Results: Big Savings & Better Performance

💰 90% Cost Savings: Avoided an expensive OEM replacement.
⚡ Faster, Smoother Operation: Enhanced machine control with a responsive touchscreen.
🔐 Extra Security: Free software backup + hardware warranty protection.

Ready to Save Big on Your Industrial Machines?

Stop wasting money on expensive OEM replacements! Contact us today for a cost-effective, high-performance HMI upgrade that keeps your machines running smoothly!

HMI Replacement of GRIFFEN BALL WARRAPING Machine

How We Helped Tayyab Traders Save Upto 90% & Restore Their GRIFFEN Machine Fast

The Challenge:
Tayyab Traders hit a wall when their REDLION HMI failed on the GRIFFEN BALL WRAPPING machine.

🚨 The Impact:
• Production halted. Every minute lost meant money out the door.
• OEM replacement? A steep 2 million, with no warranty.
• They needed a quick, cost-effective fix that actually worked.

💡 Goal: Get the machine running fast, without breaking the bank.

Our Smart Solution: A Better HMI, Built for Less:
We built the same program on an 8-inch Windows-based HMI that is smarter, smoother, and 90% cheaper.

✅ Installed BREAKNECK'S custom program to match their needs
✅ Free software backup to avoid future issues
✅ 1-year warranty on original hardware & 2-month warranty on refurbished hardware
✅ 1-month checking warranty on software

How We Did It?

🚀 Step 1: Inspection & Planning
• Diagnosed the problem on-site
• Offered two options—client chose a budget-friendly refurbished solution

🔧 Step 2: Hardware & Software Upgrade
• Removed the faulty REDLION HMI
• Installed Windows-based 8" HMI with customized software

🛠 Step 3: Testing & Delivery
• Full system test and seamless integration
• Delivered with software backup and warranty included

The Results: Big Savings & Better Control
💰 90% Cost Savings – Avoided the overpriced OEM part
⚡ Smoother Operation – Faster, more responsive touchscreen
🔐 Extra Peace of Mind – With backup and warranties

Need a Smarter, Cheaper Fix for Your Machine?
Skip the OEM costs. Get a tailored HMI solution that works better for way less. Contact us today!

BENNINGER SIZING HANDY REPLACEMENT

How We Helped Naveena Textiles Replace Their Faulty Handy Saving Upto 90% Cost Compared To OEM and That Too With Enhanced Features and Improved User Experience!

The Challenge:

Naveena Textile Mills faced a critical issue: their Benninger Sizing Handy had malfunctioned.

🚨 Impact: The entire sizing machine was non-operational, causing a complete production halt.
💡 Goal: Find a cost-effective solution to restore operations while enhancing functionality.

Our Smart Solution:

Instead of opting for a costly Benninger replacement, we designed and installed a custom Siemens HMI system with advanced PLC modifications. The results?

✅ 90% cost savings compared to replacing the original handy
✅ Enhanced control features for seamless operation
✅ Improved user experience with additional monitoring options

How We Did It?

🔹 Step 1: Conducted a site visit to assess system compatibility
🔹 Step 2: Designed and developed a custom Siemens HMI with PLC modifications
🔹 Step 3: Installed and commissioned the new system while ensuring a reversal option if needed

The Results:

💰 Massive Savings: Over 90% cost reduction compared to an original replacement
⏳ Faster Operations: New control features save valuable time
📊 User-Friendly Interface: Five additional monitoring options for improved usability
🔄 Warranty Protection:

• 1-month service warranty for refurbished hardware

• 1-year hardware warranty for new HMI installations

• 1-Month checking warranty for Breankeck’s Program

Want a Smarter, Cost-Effective Machine Upgrade?

Stop wasting money on overpriced replacements! Contact us today for a high-performance, budget-friendly solution tailored to your needs.

BENNINGER SIZING PLC MODULE REPLACEMENT

(ET-200L to ET-200S)

How We Helped Indigo Textile Mills Save Upto 90% on Costs & Minimize Downtime?

The Challenge:

Indigo Textile Mills Ltd. faced a critical production bottleneck due to a failed Siemens PLC module (ET-200L) on their Benninger sizing machine.

🚨 Impact:

• The machine stopped working, halting production and causing severe losses.

• Troubleshooting inefficiencies led to prolonged downtime.

• Maintenance delays escalated costs and disrupted operations.

💡Goal: Find a cost-effective solution to restore operations and improve system efficiency.

Our Smart Solution:

Instead of a costly full-system replacement, we upgraded the faulty ET-200L module to an ET-200S module and modified the control program for seamless integration. We also introduced on-screen monitoring for creel electrical switch boxes, significantly improving troubleshooting speed.

✅ 90% cost savings compared to a complete system overhaul.

✅ Real-time troubleshooting through on-screen monitoring.

✅ Minimized downtime with faster fault detection.

How We Did It?

🔹 Step 1: Assessed system compatibility and identified upgrade feasibility.
🔹 Step 2: Replaced the ET-200L module with an ET-200S module.
🔹 Step 3: Updated and optimized the PLC program.
🔹 Step 4: Integrated on-screen monitoring for switch boxes.
🔹 Step 5: Installed, commissioned, and tested the upgraded system.

The Results:

💰 Huge Cost Savings: Over 90% reduction in replacement costs.
🔍 Improved Troubleshooting: On-screen monitoring simplifies fault detection.
⚡ Reduced Downtime: Faster fault identification and system response.
🔧 Warranty Coverage: 1-month checking and service warranty.

Looking for a Smarter PLC Upgrade?

Stop wasting money on unnecessary replacements! Contact us today for a cost-effective, high-performance PLC upgrade for your machines.