As part of our ongoing collaboration with Knorr-Bremse, the global market leader in brake systems for rail and commercial vehicles, we are introducing a pioneering project: the development of a mobile testing system for brake systems. This innovation enables service technicians to carry out all maintenance work, tests, trial operations, and software updates directly on the brake equipment in trains – without having to use the train’s infrastructure or dismantle the devices from the vehicle.

To meet the demands of service personnel, Spangler was commissioned to design a mobile testing system for maintenance and testing purposes. It will significantly expand maintenance and testing possibilities throughout the entire life cycle.

Project Development and Implementation

Our task was to design and manage the integration of all necessary electrical components into a space-saving case solution that meets aesthetic and ergonomic standards and passes all testing and approval procedures. All electrical components – including power supply, protective devices, and decentralized peripherals – were efficiently and compactly housed in a protective case.

Technical Excellence

The device was tested under the most demanding conditions, including climate tests with dry and humid heat, sudden temperature changes, condensation, and precipitation, as well as mechanical tests for oscillation, vibration, and shock. In addition to electromagnetic compatibility (EMC), it complies not only with European but also international standards.

The Core of the Mobile Testing System

Remarkably, the control logic of the mobile testing system is in the service technician’s laptop, which is connected via USB-C and RJ45. Our development work focused on electrical design, including circuit diagram creation, and was driven forward through regular, creative workshops in collaboration with Knorr-Bremse.

Current Status and Outlook

After providing the documentation, the prototype phase has now begun, including a mock-up, two prototypes, and an initial production run (0-series). Project support will continue for several more months, with ongoing adjustments and improvements.

In the dynamic world of civil engineering, we’ve set new standards with our latest project for Implenia, a company specializing in foundation engineering. Our custom solutions have significantly improved on-site efficiency while also demonstrating our ability to precisely meet our customers’ needs.

Mobile, Innovative Solutions in Use Across Europe

The key challenge was to design a mobile system that can be easily adapted to various construction sites throughout Europe. The core of this innovation are 30 frequency-controlled pumps integrated into a specially adapted sea container. This system enables processes that were previously carried out manually to now be executed fully automatically and much faster.

Efficient Ground Stabilization in Foundation Engineering

The system is used in specialized foundation engineering work to create a stable base by forming a sealing layer directly in the ground. By injecting a special material into the pore space, water permeability is almost entirely reduced, allowing the construction of buildings with basements – such as school buildings – even in groundwater areas.

A Quantum Leap in Process Optimization

Implenia has successfully transitioned from manual to automated control systems – with significantly accelerated workflows as a result. The fully automated control and documentation of each step is a first, made possible by our software and hardware solutions.

Technical Sophistication and Customized Software Development

The control concept developed by Spangler includes not only the hardware components but also tailor-made software that integrates handheld scanners and barcodes for clear identification and documentation of work processes. This solution provides seamless documentation that is transmitted directly from the construction field to the central system.

Forward-Thinking Concepts with Wi-Fi and Mobile Applications

Special attention was paid to optimized Wi-Fi coverage, ensuring seamless network access across the entire construction field. In addition, an Android app was developed, allowing technicians to work mobile and efficiently—completely independent of stationary systems.

Continuous Optimization

Through the successful implementation of this project, we are laying the foundation for ongoing optimization and flexible adaptation to future requirements. Our role as a full-service provider for both hardware and software enables us to respond flexibly to our customers’ needs and consistently deliver tailored solutions.

For BHS-Sonthofen, a specialist in recycling, construction materials, and process technology solutions, we developed a modern control solution for a vertical dryer (an industrial drying system used for drying bulk materials or pasty substances, e.g., in the food, chemical, or pharmaceutical industry), which stands out for its exceptional efficiency and adaptability.

Advanced Control for Maximum Efficiency

The control system we designed and built consists of two cabinet sections. The core component is a frequency converter with a power rating of 90 kW, which drives the mixing spirals in the vertical dryer. This frequency converter plays a key role in the high efficiency of the drying process, as it enables precise control of the mixing motions while also saving energy.

Since the system operates in a potentially explosive (Ex) environment, we met strict safety requirements. The control cabinet itself is located outside the Ex area, while the locally installed operator panels comply with the standards for Gas Zone 1 and Dust Zone 21. This means the specially manufactured stainless steel operator panels are designed to provide maximum protection in the event of an explosive atmosphere. The special enclosures for this project were supplied by explosion protection expert Exepd to meet the high safety demands. The local operator interface allows specific process requirements to be addressed directly during operation, ensuring a high level of safety and process control.

Adaptable Automation for the Process Technology Market

The dryer itself is designed to efficiently dry various media while ensuring uniform temperature distribution and consistent moisture levels. With its double-walled, conical containers and a central agitator, the material is continuously mixed to allow even heating and drying.

This automation solution enhances process stability and reduces drying times – resulting in a significant increase in production capacity for the end customer.

We built the switch and control system for an innovative surf facility for our customer. The successful completion of the project once again demonstrated our ability to meet the specific requirements of the U.S. market. Located in Dallas, Texas, the facility combines leisure and athletic activity in one. With twelve pumps, each rated at 68 kW, it creates a powerful and authentic wave that delivers an especially natural surfing experience.

A Project Full of Passion and Technical Highlights

In addition to the technical complexity, the control cabinets were built according to the fundamental UL standards of UL508A and subsequently certified. This certificate confirms that our specially trained UL staff meet the high demands for safety and quality, and it qualifies us to carry out inspections and approvals through UL Germany. The diversity of industries and projects provides our employees with variety and opportunities for personal and professional development.

By using E-Plan P8, we were able to plan efficiently, reduce lead times, and ensure high implementation precision – thanks to optimized processes and close collaboration among all project stakeholders.

Certified and Experienced in North American Plant Engineering

Spangler has the necessary expertise and experience to meet the high standards of current regulations and build systems for the North American market. As one of the few German manufacturers, we hold the relevant certification and possess the required technical know-how.

When techniques from other fields are used in technical revolutions, it is called technology transfer. Together with our customers, we were able to achieve such a technology transfer at the waterworks of the municipality of Mühlhausen. The starting situation was the municipality’s requirement to secure the waterworks against the failure of the public power grid.

Initial Situation and Challenge

The first construction phase of the Mühlhausen waterworks was implemented many years ago with a forward-thinking approach. With the facilities available at that time, in the event of a power failure, the population had access to the water stored in the elevated tanks. A technician then had to be on-site to manually start the emergency generator and ensure the water supply. To simplify this laborious procedure and increase supply security, a stationary emergency generator has now been integrated into the waterworks.

Innovative Solution

The stationary emergency generator, with a capacity of 250 kVA, automatically detects a grid failure and starts independently. The pumping station is supplied with energy with minimal delay, and the water supply automatically resumes. Our contribution is thus a significant advantage of this system, as we were able to fully integrate the factory-prepared components of the aggregate into the existing control cabinet system.

Technical Modernization

Another step in this project was the conversion of the network form to TN. This modernization was necessary to bring the feed-in up to date. This measure not only increases the safety and reliability of the facilities but also ensures that the waterworks are prepared for future challenges.

Future Outlook

Uninterruptible power supplies are widespread in other critical areas. Hospitals, civil protection buildings, and other critical infrastructures already rely on secure supplies. Waterworks as well are increasingly included in the circle of critical infrastructures, and the issue of supply security is gaining more and more importance. At Spangler, it is therefore assumed that this implemented solution will become the standard in the future.

For our client Hecht Technologie GmbH, we successfully implemented the Small Package Filling with PCC project. This execution underscores our capabilities in automating complex systems and sets new standards in the efficiency and precision of process automation.

Partnership in Action: Hecht and SPANGLER Set Standards

The Small Package Filling with PCC project was carried out in close collaboration with Hecht for a pharmaceutical company in the Netherlands. It includes comprehensive automation solutions, including wiring diagram creation, switch cabinet production, programming, and pre-assembly at Hecht in Pörnbach. Hecht Technologie GmbH, headquartered in Pfaffenhofen, specializes in the handling of bulk materials such as granules and powders used in industries like food, pharma, and battery manufacturing. From the beginning, our collaboration has quickly developed into a productive partnership.

Tailored Solutions for Critical Applications

Small Package Filling with PCC is a tailored solution for the precise handling and packaging of cholesterol in a pharmaceutical cleanroom environment. It replaces the previous manual filling from the dryer with a suction conveyor (PCC), dosing section, and powered roller conveyors. This increase in automation level improves both ergonomics and hygiene in the process.

In this project, we planned and realized complete automation solutions, including wiring diagram creation and switch cabinet construction, adhering to the strictest hygiene and safety standards, including the implementation of explosion protection systems according to ATEX standards and cleanroom conditions. Additionally, innovative control technology was used. By using the standard library with customer modules from Hecht, we ensured consistent visualization and easy operation via the Siemens TP900 Comfort operating panel.

Integration and Safety: Technical Highlights

For the control and monitoring of the facility, four state-of-the-art control cabinets were integrated, each equipped with Siemens technology:

• MCC (Motor Control Cabinet): Control cabinet containing the motor control and main control elements.
• LOP1 (Local Operator Panel): Operator cabinet allowing the operator to control all processes under cleanroom conditions.
• RIO1 (Pneumatic Cabinet): Contains all pneumatic components and controls the precise dosing of materials.
• RIO2 (Distribution Cabinet): Serves the efficient distribution of signals and energy within the facility.

Explosion Protection and Safety

Special attention was given to the high safety needs of the facility, especially regarding explosion protection (ATEX). The facility must be safely operable in environments where explosive atmospheres are possible.

From Concept to Reality: Installation and Commissioning

After successful pre-assembly and initial tests in Pörnbach, the facility is transported to the end customer’s site in the Netherlands for final assembly and commissioning. This phase is also accompanied by SPANGLER technicians to ensure a smooth start of production.

The project “Small Package Filling with PCC” not only illustrates our technical expertise but also our commitment to innovative solutions tailored to the individual requirements of our clients.

At a ceremonial event, we were presented with the “Blühender Betrieb – Blooming Business” award by the Bavarian State Ministry for the Environment and Consumer Protection. This award reflects our long-standing commitment to environmental protection and biodiversity.

Commitment to the Future

Under the leadership of our Managing Director, Tina Lambert, we have implemented various measures to promote biodiversity on our company premises in the Altmühltal Nature Park. Our initiatives range from creating flowering meadows to planting fruit trees and establishing habitats for bees and lizards. Tina Lambert emphasizes that this commitment represents a deeply felt obligation to the next generation and is an expression of our effort to create sustainable and livable work environments.

Praise from Local and State Representatives

Dagmar Schmitt from the Bavarian State Ministry for the Environment and Consumer Protection and Bernd Mayr, the Mayor of Dietfurt a. d. Altmühl, have commended our efforts. Mr. Mayr sees Spangler as a role model for local businesses and hopes for widespread adoption of our approach. Ms. Schmitt highlighted the importance of our commitment in the fight against species extinction and for the preservation of natural habitats.

Sustainability in Action

In addition to promoting biodiversity, we rely on sustainable energy sources such as geothermal energy and photovoltaics to further reduce our carbon footprint. These measures demonstrate our continuous commitment to environmentally friendly technologies and underscore our dedication to ecological responsibility.

Thanks to Our Employees and Partners

A special thanks goes to the team from Regens Wagner, particularly their “Grünen Daumen -Green Thumb” team, who have been instrumental in maintaining our green spaces. Additionally, various Spangler employees were involved in transforming our new outdoor area, significantly contributing to meeting the requirements of the State Ministry.

Small Gesture, Big Meaning

As a token of our appreciation and to emphasize the importance of bees to our ecosystem, every guest at the event received a jar of freshly harvested honey from our own beehives. This honey is regularly produced by our in-house beekeeper. This is just one step on the long road to environmental protection. Our goal is to continue to lead in sustainable and environmentally friendly technologies and to integrate them into our projects and products in the future.

In the presence of our entire workforce, we were able to open our new cafeteria, which is more than just a place for a lunch break. This newly designed space symbolizes our vision of creating a central meeting point where employees from all departments can meet and exchange ideas. We want our employees to feel not only productive in their work environment but also particularly comfortable.

A Place for Coming Together and Exchange

Our new cafeteria serves as a central meeting place that bridges the gap between manufacturing and office spaces. It is important to us that this space not only represents the physical center of our company but also provides a place where colleagues from different departments can come together in a relaxed atmosphere. The direct access to the outdoor area adds another dimension to this space, offering an additional opportunity for relaxation and informal communication.

Focus on Relaxation and Health

In our cafeteria, we offer free fresh fruit, vegetables, water, tea, yogurt, and healthy snacks in the form of a nut bar to support our staff in leading a healthy lifestyle. Additionally, a varied and diverse menu is in the planning stages, which all our employees can conveniently order through a dedicated app. The meals will be prepared and will be ready at the desired time in the cafeteria. With this option, we want to support our employees in fully concentrating on their well-deserved break without having to worry about getting food. Moreover, a staff grill is available, which every department can use as they wish to make their break even more enjoyable.

Redesign with Heart and Craftsmanship from the Region

The planning and realization of the cafeteria was a project carried out with great attention to detail by Prokurist and HR Manager Cornelia Hofmann, along with a reliable team of local craftsmen. This reflects our personal commitment to creating an appealing and functional space that meets and promotes the needs of all employees while also providing a suitable place for our customers, who may stay with us for several days during offer discussions, planning sessions, or FATs (Factory Acceptance Tests).

Invitation to the Next Power Date

External visitors are also very welcome to get a personal impression of our facilities. As part of our regular “Power Dates,” we open our doors and invite all guests to become part of our ever-growing community.

With numerous employees participating and wonderfully sunny weather, our excursion day began, impressively demonstrating our collective strength as a team and our partnership with HUBER SE. Starting in our newly opened cafeteria, we enjoyed fresh wraps and cool drinks before visiting the HUBER SE plant in Erasbach together.

Gaining Insight Through Proximity

The tour led by Dr.-Ing. Oliver Rong (Deputy Chairman of the Board and Board Member for Technology & Production) and his team provided us with deep insights into Huber’s advanced technologies and production processes. This visit not only strengthened our knowledge but also the personal connections between our companies. Mutual understanding is the foundation for successful business relationships and is reflected in our appreciation for the challenges and successes of our customer and partners.

A Special Cooperation

Our collaboration with Huber began in 1987 when we built the first control system for Huber, then based in Berching. Since then, both companies, Spangler and Huber, have grown steadily. Both companies have also evolved together. Our goal has always been to be a crisis-proof and innovative supplier for Huber, to remain competitive together and to pursue a long-term and partnership-based path.

Team Spirit and Joy in Shared Success

After the inspiring plant tour, we continued to the Cosmos Arena in Ingolstadt, where we demonstrated our skills in mixed teams at bowling. The relaxed competitive atmosphere and the division into many small groups created tension and fun. The winners of the tournament were rewarded with Spangler sports bags in a cheerful award ceremony.

Culinary Conclusion in a Traditional Setting

The day ended with a joint dinner at the regional restaurant Himmelreich, enjoyed in a relaxed beer garden atmosphere. These moments of exchange are essential for strengthening the social bonds within our team and across departmental boundaries.

Outlook: The Power of Community

This day not only brought fun and joy but once again showed us the importance of personal contact and the direct experience of other work environments. We are convinced that such experiences lay the foundation for innovation and shared success. Our company outing was more than just a day of relaxation – it was a reflection of the vibrancy of our corporate culture and the commitment of each individual.

Our customer ISV Umwelt UG has equipped the sewage treatment plant Felsberg, a town in the North Hessian region of Schwalm-Eder, about 20 kilometers South of Kassel, with a new centrifuge for sludge dewatering. SPANGLER supplied the control and automation technology for this project.

The dewatering centrifuge

The centrifuge is fed with a mixture of thin sludge to be dewatered and flocculant previously prepared in a dosing station. Due to the high speed and the resulting centrifugal force in the centrifuge, the suspension is separated. Because of the higher density, the solid particles collect on the outer wall of the drum and the less dense liquid in the center of the centrifuge. The discharge screw inside the centrifuge drum rotates at a higher speed and thus conveys the settled particles to the solids discharge. The liquid drains off at the opposite side.

With Spangler towards Industry 4.0

For an optimum dewatering result a precise regulation of the quantity ratio between thin sludge and flocculant is necessary. The flow sensors and further sensors required for this are connected via the IO-link to the Siemens PLC (S7-1215C). The IO-Link devices can be centrally parameterized via the TIA portal and diagnostic information can be read out. In case IO-link devices are exchanged, the previous configuration is transferred automatically to the new sensor. Thus, standstill times can be minimized and the personnel expenses can be reduced.

For monitoring and display purposes, current machine data are transferred via a bus interface via S7 protocols to the on-site control system. The plant is operated via a touch panel TP1200 which is installed in the control cabinet front. For the remote access operation, the user interface via Sm@rt-Service can be transferred to an internet-enabled end device (e.g. laptop, mobile phone, tablet, …). A LTE modem enables access both from the specially created local W-LAN network and via VPN from the internet. The VPN-tunnel enables ISV Umwelt UG and Spangler to access the system remotely to offer for example service support or to install program updates. Furthermore, to save costs, the remote access was used to carry out the start-up.

The water treatment system of our customer Bertschi AG in Switzerland actually works perfectly after the tank has been cleaned. The water added with chemical substances is treated and can therefore flow back into the sewer system. However, most components, including the control units, are outdated. So, it was time to bring the plant up to the latest technical standard so that the process can continue to run smoothly in the future, according to the customer’s statement. Spangler Automation was then commissioned to modernize the water treatment plant with the Retrofit-Service.

Demanding process of water treatment

With the cleaning of the tanks, chemical substances are added to the water. Therefore, it must not be returned to the sewer system without prior treatment. During treatment it passes through various areas, one of them is the treatment in the supply container. Here, the waste water pre-treated by the reaction tank is gradually fed into five supply tanks, aired and the sediment deposited on the bottom is removed. In the next step the waste water flows into so-called aeration tanks in the biology area. Here, urea, defoamer and phosphoric acid is added manually for the correct pH-value. Afterwards the pretreated waste water flows into the two ultra filtration streets and is pumped through the filtration circle for cleaning and filtering. The filtered waste water flows into the permeated tank. After previous fine treatment, the water is now clean and can flow back into the sewer system.

Extensive retrofit of the control technology

In agreement with the customer, a functional specification sheet of the plant process was established. Thanks to the detailed pre-planning the visualization and programming could be implemented smoothly. The special aspect about this order was the short-term and simultaneous application of two PLCs running in parallel in one plant. It was possible to switch between both controls. This made it possible to switch to a new redundant control system quickly and safely. Before the final conversion to the new PLC was concluded, the plant was tested intensively in advance with the help of a remote simulation. After the first test run, it was already possible to switch from the old control system to the new one. Two Siemens PLC S7-1500-R and one ET200SP as decentral periphery were applied. Additionally, two Siemens operation devices HMI TP1500 were installed.

Pondus® Verfahrenstechnik GmbH has commissioned Spangler Automation to install a new disintegration plant in the sewage treatment plant Erlangen. This is a process for the digestion of microorganisms in sewage sludge, the so-called thermal-chemical cell disintegration. Due to a preliminary project, many parallels could be drawn, and the project could therefore be implemented relatively quickly.

Thermal-chemical cell disintegration

With the process of thermal-chemical cell disintegration (hydrolysis) sewage sludge is heated up in a special reactor and with the addition of base, the cell membrane is broken down to the greatest possible extent. In this way, the organic residual material in the digested sludge is reduced and dewatering is improved. The dry proportion of the dewatered sludge is increased and the amount of sewage sludge that must be disposed is reduced. The residual heat included in the sludge after heating is re-used in the following process steps such as digestion.

Versatile automation and control technology

Spangler Automation has planned, produced and programmed the automation technology for this system. Three control panels were equipped with the central Siemens PLC S7-1516. In addition, the plant was connected to the control system that can be operated locally. With the Siemens IPC477E 22 inch a clear layout was created and enables intuitive working at the plant. The coupling of the three control panel fields was implemented with the decentral interface module ET200SP. The multifunctional Siemens measuring instrument PAC3220 is used for the energy analysis; power and voltage values are online available. The continuous and equal feed of the plant technology is guaranteed by pumps, controlled by two frequency conformers.

Spangler Kids Day – a great initiative that provided a unique insight into the working world of parents for the youngest members of the families.

Spangler decided to take over the care of their employees’ children for half a day because of the school holiday, on which the parents had to fulfill their professional duties. The Spangler Kids Day took already place in the past and was not only initiated to offer a special event for kids during a holiday, but for the children to get to know the working places of their parents in a relaxed atmosphere.

Success factor family

With the Kids Day, the management of Spangler stresses its strong commitment for the compatibility of work and family, which has already earned them an award as a family-friendly company from the Federal Ministry for Family Affairs, Senior Citizens, Women and Youth.  The event offers the children the opportunity to experience their parents from a new perspective and shows the strong focus on appreciation of the family by the company.

The day started with a warm welcome of the children, a group picture and an amusing introduction game to get to know each other. Then the motivated kids prepared a healthy breakfast together with the Spangler team.  In this way, the day started with fun and a sense of community.

The highlight – save use of electricity

The highlight of the day was definitely the fascinating experiments with self-made battery cardboard figures. Two apprentices, who are currently doing an apprenticeship to become an electronic technician in automation and systems technology, instructed the kids and explained the experiments.

As in real working life, the findings were checked and then recorded. This practical learning emphasizes Spangler’s commitment to support the training, especially in the natural scientific field.

Inspiring future experts

The Spangler Kids Day ended with another highlight, when the kids visited their parents‘ workplaces and gained a first insight into their daily working lives. This initiative stresses Spangler‘s goal, not only to show the parents their appreciation, but also introduce the children to the possible workplace of tomorrow.

At the biogas plant in Gordemitz Spangler GmbH realized the automation, starting with engineering, to PLC programming, creating the control system, to production and start-up. In all, 21 control cabinet fields were planned and projected, which are distributed to different buildings.

Energy for up to 4 000 households

The heart of the automation is software which is individually adjusted to the biogas production. For process monitoring, Spangler uses the WinCC control system by Siemens, which visualizes the operation of the whole plant. Special detail: in addition to the conventional computer, the plant can be controlled via WLAN with the help of a tablet PC. As control, a SIMATIC Siemens S7 was installed.

A solids feed with conveyor belts and screws was integrated in the biogas plant which is operated by BALANCE GmbH.  Various substrates are processed, including chopped corn, whole plant silage, grass silage and dry chicken dung. There is the possibility to feed the plant via an additional pit with cattle slurry or other liquids. A small part of the biogas produced is used for the heat production of the digestate container of the plant. The remaining bigger part of the biogas produced is fed into the natural gas network as bio methane with the help of gas treatment with downstream gas injection. In all, it amounts to nearly 700 cubic meter bio methane per hour, with which on average up to 4 000 households can be supplied.

Being informed all the time

With the integrated fault messages, the plant operators have the possibility to be up to date around the clock. Fault messages can be transferred to the operation mobile phone via SMS, mail or voice message. The messages are transferred in plain text, that means the fault message text of the control system shown is transferred 1:1. By default, the SMS alarm is used. Additionally, there is an escalation variant. If a user cannot be reached or if he or does not answer within a certain time, it will automatically be switched to the next receiver.

If a customer was informed about a failure at the plant, he or she can switch remotely on the operating computer. The remote access can take place from any internet-ready device. After access, the customer has the same view on the operation computer as at the plant.

Spangler is an UL-listed manufacturer of control systems and thus certified, to produce plants for the North American market. A regular inspection by UL Germany guarantees a consistently high standard based on current standards.

Control cabinet construction according to UL508A

The UL508A is the relevant standard for the construction of control cabinets in North America (Industrial Control Panels). This differs fundamentally from the widely used IEC standard, as not only the plant, but also the production process is checked.  For the installation of a plant the acceptance by the AHJ (Authority Having Jurisdiction) is necessary. Besides control cabinets for General Use, Spangler mainly designs controls for Industrial Machinery where the NFPA79 Electrical Standard for Industrial Machinery is observed as, in addition to UL508A, there are other requirements such as door locking.

Control cabinet construction in Ex-area according to UL698A

With application in explosion-proof areas (hazardous locations), special requirements according to UL698A must be for risk avoidance. As only one of few companies in Germany, Spangler holds the extended certification and the know how to produce control cabinets for control systems of plant parts in the Ex-area.

On-site acceptance

In North America it is required by law that the local responsible authority AHJ (Authority Having Jurisdiction) carries out the on-site acceptance whereas in countries like in South America, the Middle East or in Asia the requirements are from the customers themselves. By marking the control cabinets with UL-listed labels, Spangler ensures a smooth process of inspection and thus avoids any delays with start-up. Spangler has nearly 20 years of experience with planning, production, certification and documentation of control systems for the North American market and offers further support with electrical planning.

Three Spangler UL specialists have concluded the MTR test (Manufacturer Technical Representative) at UL Germany and regularly take part in trainings. The examination must be repeated every three years. In this way, Spangler can guarantee consistently high quality. The specialists have already designed and produced many control systems – like for example hydrogen filling stations in the USA or sewage treatment plants in the Middle East – in accordance with UL standard.

Waste water heat utilization is becoming increasingly economically interesting due to the rising energy prices. Thus, in the municipality Schallstadt, near Freiburg in the South of Germany, the favorable location of the new building area near the sewer channel was used to install a system called ThermWin which was developed by Huber SE.

Spangler has planned, produced and programmed the automation technology. Building owner and operator is Energiedienst AG.

Using thermal energy from waste water

The nearby channel collects the waste water from the neighboring communities Ebringen and Pfaffenweiler. For extraction of the waste water, a Huber pumping stations screen ROTAMAT® RoK4 was installed underground, so it is invisible. It is in the first position of the closed solids cycle and is for cleaning of the waste water.  Coarse material is removed and returned to the channel. Pumps convey the energy-rich waste water to the Huber heat exchangers RoWin. The waste water heat exchangers have an automatic self-cleaning. A constant heat transmission to a storage silo of 500 m³ is guaranteed The RoWin together with the ROTAMAT RoK4 results in the Huber ThermWin procedure. With the heat generated a residential area with approximately 200 apartments and the town hall is heated. Fossil energy sources are not used, that sustainably protects our environment.

Technical know-how

In the main control cabinet, the Siemens control PLC S7-1512SP-1 PN was installed which is operated via the Siemens operation device TP700 and which enables logging of process parameters on USB stick. The connection to the pump station was implemented with a decentral interface module ET200SP. Both plant parts are connected via a fiber optic-connection. Such an advanced machine requires an innovative control system, which Spangler GmbH has realized with this project. There is a temporary buffering of the 24VDC PLC-voltage to guarantee a safe process parameter storage in case of voltage breakdown. Additionally, the plant is connected via Sm@rtServer-Funktion to the web-based remote visualisation.

Modern industrial plants are often enabled by industrial communication networks to communicate and work in a network. The usual office network technology (IT world) differs significantly from the technology used in control systems in the OT world (Operational Technology). In recent years, however, OT and IT have increasingly merged, referred to as “Industry 4.0″.

OT and IT – Industry 4.0

Due to the constantly increasing networking of OT and IT, Spangler used the IEC 62443 standard as a basis for linking both sides and still guaranteeing the security of the systems. IT Security in machines and systems must be viewed holistically. A risk-based segmentation within the overall system is important. In the first step, Spangler Automation works out a customer-specific cell protection concept for the control cabinets and then implements this together with the customer.

Holistic view – standard IEC 62443 as a basis for IT Security

Networking in the field of sensors and actuators has been indispensable in industry for years. Up to now, however, industrial systems have been isolated and separated from the office networks. This has changed completely in recent years: Industrial networks have been connected to other IT components. This makes the island network vulnerable. There is a trend towards connecting cloud infrastructures in order to use them to open up new business models.

On the other hand, networking leads to opening and implicates the risk of misuse by unauthorised persons. In addition to a digitisation strategy, every industrial company or municipality therefore also needs a strategy to secure the production process and its own know-how to secure the business model. The IEC 62443 standard was defined for industrial IT security. It contains an established, implementable procedure model for an industrial cyber security strategy and is therefore clearly superior to uncoordinated individual activities. The essential parts of the standard have been published since the beginning of 2019 which gives users of the standard sufficient planning certainty.

Spangler Automation has intensively dealt with this standard. It now serves as the basis for IT security in the control cabinet and the system. The focus here is the segmentation of the system network. Therefore Spangler integrates a firewall into the control cabinet upon customer request which monitors communication and prevents attacks on the PLC and thus ensuring the continuity of the entire system. The firewall guarantees mutual protection – on the one hand for the system inside the control cabinet and on the other hand for the customer’s entire system. This prevents unauthorised access. At various customer training courses at the beginning of the year, Spangler provided detailed information and explanations about IT security.

Basically, a network subdivision with different function groups is always an advantage. If the control cabinets cannot communicate with each other, no malware can be passed on. However, as OT and IT are merging more and more, the systems are becoming increasingly internet-enabled and network-enabled and Ethernet-based fieldbuses such as PROFINET, EtherCAT and Modbus-TCP are therefore being used, certain protective measures must be defined.

Patch management

Patch management includes the planning, procurement and testing of patches. A patch is a correction delivery for the software to correct errors, mostly to close security gaps that have become known or to retrofit functions that were not available before. This means that the software inventory is constantly kept up to date. This is possible by the regular import of updates. Spangler Automation can support its customers to import updates e. g. via remote access or with remote maintenance modems. The holistic view is paramount again. It is decided in advance which update is relevant for which customer, how to inform the user or how to import the updates. For IT security it is important to be properly prepared. Our in-house specialists will be happy to support you. Get in touch with us for important preventive measures.

We inform you about a personnel change in our company. Our long-term employee Franz Achhammer has taken over Sales management on 01.04.2023.

Since 2006 he has been working as a technical sales expert in our company, for one year already as deputy manager of the sales department. During these 17 years of his sales activities, he has been able to build up a large customer base through his high commitment to the needs of his business partners. The solid, long-term co-operation with customers from the various industries has given him a wealth of experience which he can count on in contact with customers.

Franz Achhammer has a remarkable expertise and has already been active in various areas. As new sales manager he is solution-oriented and will continuously work hard for his customers.  Recent special issues include renewable energies and emergency power supply.

Besides his demanding work, Franz continues to maintain his honorary work as examiner at the Chamber of Crafts. He is happy to take his time for his engagement for the next generation in the apprenticeships.

We are pleased to have a committed sales manager from our own ranks and wish him every success in his new tasks.

The traditional brewery Lammsbräu in Neumarkt in the Upper Palatinate is a long-term customer of SPANGLER Automation. Within the scope of an extensive retrofit programme, the process of malt kiln was completely equipped with new hardware, the wiring diagram and the software were revised and several plants were connected to the existing control system.

State-of-the-art automated handicraft

For more than 16 years Spangler Automation has been delivering Lammsbräu with hard and software, like for example the automation of the water treatment and fresh water well pumps. In 2021 it was necessary to modernize the process of malt kiln. The kiln drying of malt is a drying process which essentially affects the taste and colour of the beer. To ensure the product characteristics and the quality in future as well, the whole process had to be brought up to date. Spangler used the old documents of the drying plant and conveyor plant as a base and with the help of EPLAN developed a new, digitised wiring diagram that was designed smaller and more clearly arranged.

Spangler has chosen the programming and the user interface of the touch panel in a way that the functionality was increased, and a finer setting of the programmes was enabled.  The brewers’ experience was included in the design of the process flow which allowed a more user-friendly design. In addition to the new control cabinet for the control Siemens S7-1200, on-site control boxes were assembled.  These pushbuttons determined for the manual operation of the engines are available for the staff as alternative to the automatic operation or the touch panel. The extended retrofit makes it possible to connect the drying chamber and the conveyor belts to the control system, which already controls the other plants of the malthouse.

Precise preparation for a quick implementation

The electrical assembly of the control cabinet and the start-up had to be carried out during the yearly maintenance of the building at Lammsbräu, that means within three days. This required detailed planning and exact preparation, from the software to the last wire. Beyond the requirement of start-up, Spangler programmers accompanied the first drying process and took over fine adjustments.
Lammsbräu can now count on a reliable supply of spare parts, higher safety provisions and automated-backed processes. An optimal retrofit package to guarantee the quality of beer appreciated by the customers.

SPANGLER Automation has been a Siemens Solution Partner for several years in the sectors -Factory Automation- and -Industrial Strength Networks. As one of 20 companies worldwide, Spangler now went through the certifying process also in the industrial sector Water & Wastewater and was awarded with the official certificate in June 2022.

Competitive advantages for Spangler customers

Spangler is a longtime certified Solution Partner. After the sectors “Industrial Strength Network“ and “Factory Automation“ now the certificate for the industry module “Water & Wastewater“ was achieved. Spangler convinces in this industrial sector with a long-term expertise in automation of water treatment as well as environment technology. As only one of 20 companies worldwide, Spangler can now actively access Siemens’ product and system experience and support its customers with their different requirements even better.

Close exchange as a benefit for Spangler customers

Spangler’s industry and application know-how paired with Siemens’ range of services in the field of automation and drive technology results in tailor-made solutions for Spangler’s customers. Siemens offers trainings and courses for Spangler employees as well as professional technical support which is exclusively available for Solution Partners. The close cooperation and common on-site visits save the customers a lot of time and ensure the productivity and availability of their plants.