When SKU variety increases and product changes become more frequent, line planning becomes expensive. Our modular machine KMO is based on a modular core system and grows with plug and play modules, for short format changes and stable processes.
Modular Lines, flexible from the start
When SKU variety increases and product changes become more frequent, line planning becomes expensive. Our modular machine KMO is based on a modular core system and grows with plug and play modules, for short format changes and stable processes.
Future-proof and maximally flexible
Diverse requirements demand a machine concept that can grow with them. Frequent product changes, new variants, and different packaging types place high demands on flexibility and cost-effectiveness. This is precisely where a scalable design determines efficient and future-proof processes.
With the modular machine KMO, you can configure your packaging solution exactly according to your current needs. Thanks to standardized modules and the fast transport system with floating movers, the system can be expanded and adapted to new requirements at any time – from classic applications to cleanroom requirements. This way, you remain flexible, efficient, and secure in your investment over the long term.
Typical Starting Situation
Typical for growing product portfolios: high quantities, frequent product changes, and multiple types of packaging. This is exactly where modularity shows its strengths.
Example challenges:
Coresystem
Our modular machine concept consists of a core system that can be flexibly expanded with "plug & play" modules
Module 1
Module 2
Module 3
Module 4
Module 5
Module 6
* Downstream processes
Module 7
Module 8
Performance data at a glance
Quick and simple process extension with new modules (within one work week)
Easy expansion of the transport system
Performance increase and modernization possible
Investment security regarding future market requirements
Fast format changes
Multiple packaging types on one machine
Functions can be switched on and off
Automatically adjustable format parts
Low integration effort for modules (1 day)
Individual, simple configuration of independently functional modules
Easy coupling of the modules via standard interfaces
Development of project-specific processes and modules
Output: up to 300 packages/min per functional module – flexibly scalable
Format change: from 5 min., depending on machine size and automation level
Quick response time
Service-friendly, ergonomic design
Digital twin, e.g. for commissioning/replacement of modules
Cost-effective design of functions such as grouping, marking, inspection, gluing
Compact and versatile mover format parts
Machine expansion to meet increasing production requirements
Professional project management
Short delivery time for pre-assembled modules
Clear integration process
High productivity and OEE
Long service life
Long-term service support
From modular to turnkey line
Many KMO projects start modularly and grow into a line. If End of Line, logistics, labeling, inspection, or IT OT integration are also required, we take on the implementation as a complete system.
This turns a modular KMO configuration into a Turnkey Solution along your process chain, with clear interfaces, coordinated technologies, and stable production results.
Sustainable machine technology
With KOCH, you reduce material usage by up to 30%, use monomaterials, and achieve your ESG goals – without compromising on protection or appearance.
By modular mechanical engineering, we mean a machine concept in which prefabricated functional modules are combined into a line. The centerpiece is a core system with mover transport system as well as overarching control logic including HMI. The modules are integrated via plug & play and can be added, exchanged, or rearranged as needed without having to completely rethink the entire plant concept.
Yes. You can deactivate individual modules via the user interface (HMI) and thus adapt the process flow to your current production, for example in the case of fewer variants, reduced capacity, or for servicing. Alternatively, modules can also be removed if you want to make the setup permanently leaner.
KOCH machines are fundamentally designed for low-maintenance, service-friendly construction. This is especially relevant for the KMO, because modular lines are only economical if accessibility, ergonomic maintenance access, and quick changeovers are properly addressed. That is why the system is designed so that maintenance, cleaning, and format changes are practically possible without unnecessary downtime.
Modularity is a sustainability lever, especially over the life cycle: Instead of replacing an entire machine, you can expand or modernize specifically where new requirements arise. This reduces investment risk, avoids premature replacements, and supports a long-term period of use. Additionally: Convertibility and expandability are explicitly intended as sustainability aspects of the modular concept.
In modular mechanical engineering, the concept deliberately aims for low format part costs and low complexity. Format changes should be quick and reproducible so that frequent product changes (e.g. many SKUs, small batches) do not become a cost trap. In practice, this means: fewer parts, easier changeover, clear logic and consultation by KOCH to define the most sensible format strategy for your packaging materials/products.
A key advantage of modular lines is project and planning reliability: Thanks to pre-assembled modules and a clear integration process, implementation time can be significantly reduced. As a rule, you benefit from shorter delivery times compared to classic fully customized systems and from a structured acceptance (FAT) including prepared documentation and tests.
Yes. The KMO is designed as a complete system to meet industrial safety requirements. In a modular concept, it is especially important that safety is not created “piece by piece,” but is considered systematically, including clear interface logic between the core system and modules. Accordingly, integration, protection concepts, and operating logic are designed so that modules can be safely integrated into the overall system.
The KMO is designed for high performance with high variant flexibility. Depending on the type of packaging, up to 22 cycles per minute are possible, and the output is scalable based on the number/type of functional modules. Standard modules are dimensioned so that the line can be set up compactly and logically, while additional or duplicate modules can be integrated for increased performance.
Future-proofing in modular lines arises from two factors: technology level and adaptability. The KMO is designed so that new packaging types, processes, or quality requirements do not necessarily mean a completely new project, but can be implemented by adding additional modules. This is exactly where KOCH applies its turnkey logic: requirements change, and the line grows in a structured way.
Do you want to get started quickly, with proven technology and clear performance data?
Do you need special features that go beyond the modular system?