Machining (as if) on rails
At the headquarters of the Pharma Liquid division in Crailsheim, the Syntegon Group develops and manufactures high-quality, bespoke solutions for the sterile filling of liquid and powdered pharmaceuticals. The mechanical engineering department recently implemented a clamping concept from Gressel for the production of associated A-parts, thereby significantly reducing set-up times.
When clamping workpieces on a “DMF 360 I 11”, one of the key machines in the mechanical production facility in Crailsheim, Bruno Stark’s team faced significant challenges just over a year ago. Although the modernisation of the production facility had seen a 3-axis machining centre replaced by a 5-axis machine, the clamping fixtures used up to that point continued to be employed. “This led to very significant limitations,” emphasises the technology expert. “For instance, the vices’ lack of 5-axis capability reduced accessibility, and the frequent set-up was extremely time-consuming.” On average, this took 5 hours across two shifts, and in special cases even up to 7 hours. Furthermore, chip build-up made cleaning, operating and changing the clamping devices more difficult. Work was further slowed down by the frequent transport of the vises by crane. Last but not least, the lack of standardisation in the clamping systems meant that custom fixtures had to be manufactured and components also had to be machined externally. Action was required not only for the flexible production of A-parts, but also for a “fast track” that Syntegon has established for spare parts and urgent projects.
There could only be one
The mechanical manufacturing facility in Crailsheim is highly specialised and primarily machines stainless steels and various engineering plastics. Given its size and flexibility, the DMF 360 I 11 plays a central role in this process. After all, workpieces measuring up to 3,600 x 1,100 x 1,100 mm and weighing up to 8 tonnes can be machined on four axes with a B-axis. The 5-axis machining using an integrated NC table is designed for components with dimensions of up to 1,400 x 1,050 mm and weighing up to 2 tonnes. To make production significantly more efficient, Syntegon sought a clamping concept for the DMF that had to meet a whole range of requirements: “Not only did it need to be quickly convertible between long-bed and 5-axis machining and have a modular design. It also had to be easy to clean and user-friendly, as well as allow for flexible positioning of the vices,” Stark explains. An evaluation of several suppliers quickly led to the decision in favour of Gressel, as the Aadorf-based company was simply the only manufacturer capable of meeting all the requirements. Syntegon and Gressel worked closely together to implement the bespoke solution, involving, for example, the machine operators and NC programmers.
Versatile and easy to handle
The result was a modular clamping concept based on existing zero-point clamping systems. The first component to be developed was a set of flat guide rails, which, as a bespoke solution, “were manufactured in segment lengths of 400 and 500 mm with an accuracy in the hundredths of a millimetre range”, explains Frank Scheurer, distribution engineer at Gressel. “Rounded ends ensure that the segments do not need to be removed, even during 5-axis machining. At the same time, the contours are optimised so that chips do not become lodged.” The guide carriages, which follow in the assembly, are also custom-made and manufactured to a high standard of precision. They are clamped on the operator side with a screw, with a grid and numbering system facilitating positioning. Smooth surfaces and an open design ensure easy cleaning.
As a standardised interface to the workpiece, Gressel’s new 5-axis centric clamping vises C5X feature a flexible clamping range. “With a base body length of 400 mm and a jaw height of 142 mm, they are used here for clamping ranges from 10 to 300 mm,” Scheurer continues. Essentially, the C5X offers a flexible modular system with body lengths of 300, 400, 500, 600 and 800 mm and jaw heights of 142, 181 and 252 mm, the versatility of which Gressel further enhances through the use of the jaw range from the “C2.0” centric clamping vise. Reversible grip jaws are thus available, as are adapter and swivel plates or prismatic jaws, with the respective jaw change being carried out via two screws. “A clamping force of up to 40 kN ensures reliable clamping of workpieces without pre-stamping. The fact that this clamping force is transmitted in full to the component is guaranteed by the top-mounted spindle,” emphasises Scheurer. The spindle can be easily replaced using a quick-change system, which provides a basic clamping stroke of 120 mm for every clamping block length. The clamping range can be extended depending on the base body length, achieving a maximum clamping width of 691 mm with the longest base body length.
80% of the component range covered
With the introduction of the new clamping system, the mechanical production department in Crailsheim has achieved significant improvements. Set-up times have been reduced from an average of 5 hours to around 2 hours, and for individual parts, the set-up time has even been cut from 1 hour to 5 minutes. Based on this time saving alone, the clamping system pays for itself within a year. At the same time, flexibility and efficiency have been significantly increased, as the new system covers around 80% of the parts range. “This also includes complex or large-format components, which no longer need to be manufactured externally,” explains machine operator Eugen Müller. “In addition to efficiency, ergonomics and occupational safety have also improved, as each vice no longer needs to be moved by crane and operation can be carried out comfortably from the floor.” The C5X has replaced five different old clamping devices. The enclosed system also prevents undesirable chip build-up and facilitates cleaning, right through to automated execution. “Not least, the integration of 3D models into CAM systems has simplified work preparation and NC programming,” says Harald Brunner, NC programming team leader. “This now enables virtual set-up planning, and the numbering assigned to the stops simplifies the positioning of the clamps.”
A key factor in ensuring competitiveness
The next steps involve extending the clamping concept to other machines and international sites. In Crailsheim, it is also conceivable that the system could be used in a scaled-down form on 3-axis machines. Syntegon and Gressel are currently working on the development of prism jaws for larger diameters up to 150 mm and VS jaws with a clamping range exceeding 400 mm, so that even more parts can be manufactured in-house. As the modular approach allows components to be used across different machines, further cost reductions are expected. Overall, the new clamping concept is already a decisive factor in securing Syntegon’s competitiveness.
About Syntegon
Syntegon is a leading global technology company and a strategic partner to the pharmaceutical, biotechnology and food industries. With a strategic focus on the growing pharmaceutical and biotechnology sectors, Syntegon plays a key role in global healthcare. The company offers in-depth process expertise and mission-critical technologies for the safe, efficient and compliant production of vital medicines. In the food industry, Syntegon is renowned for its fast and highly precise packaging solutions, which enable manufacturers to increase their efficiency and product quality. Through its global service business, the company supports more than 70,000 installed systems with a comprehensive lifecycle offering that ensures uptime, efficiency and long-term value. In the 2025 financial year, Syntegon generated revenue of €1.75 billion. Headquartered in Stuttgart, the company employs 7,300 people across 49 locations in more than 20 countries. With over 160 years of industry expertise, Syntegon delivers solutions that make a decisive difference, helping people to live better, stay healthy and trust the products they rely on every day.
The Crailsheim site
Crailsheim, in north-eastern Baden-Württemberg, is the Syntegon Group’s largest site. The headquarters of the Pharma Liquid division acts as a strategic partner to the global pharmaceutical and biotech industry, providing innovative processes, technologies and sustainable solutions. In Crailsheim, Syntegon develops and manufactures high-quality, customised solutions for the sterile filling of liquid and powdered pharmaceuticals. The portfolio includes individual machines, complete lines and integrated systems. These can include, for example, filling and capping machines or barrier systems. Syntegon offers high-quality inspection technology for the quality control of liquid and lyophilised pharmaceuticals. As a provider of complete solutions, the range of services in Crailsheim includes consultancy, design and installation, as well as bespoke services in the areas of qualification, validation and after-sales support.
