Industrial mechanical redesign is used to correct problems of energy consumption, vibration, premature wear and lack of precision in machinery that keeps running but no longer works under efficient conditions.
Many industrial lines keep operating for years with oversized systems, deformed structures or components that cause repeated breakdowns. The problem is often not the operator, nor the maintenance, nor the PLC. The problem lies directly in the machine’s mechanical design.
Instead of replacing the whole installation, many companies are opting to modify critical components, reinforce structures, redesign transmissions or replace hydraulic systems with more efficient electromechanical solutions.
How to optimise the performance of industrial machinery through mechanical redesign
Mechanical redesign makes it possible to reduce electricity consumption, vibration, premature wear and downtime without having to replace the whole production line.
In sectors such as recycling, agro-industry, industrial presses or heavy machinery, modifying critical components usually brings immediate improvements in productivity and operational stability.
At Kernova, these types of projects are carried out through advanced mechanical design and FEM validation, analysing stresses, vibration, deformation and dynamic behaviour before manufacturing the final solution.
Many repeated breakdowns are not caused by natural wear.
The origin is usually poor load distribution, structural deformation or oversized systems.
What problems usually indicate that a machine needs a mechanical redesign
Many industrial plants have spent years attacking symptoms rather than the root of the problem. They change parts, adjust parameters or increase preventive maintenance, yet the machine keeps working outside reasonable conditions.
There are quite clear signs:
- High electricity consumption compared with similar machines.
- Constant vibration during certain phases of the cycle.
- Repeated failures in bearings, guides or transmissions.
- Loss of precision in positioning.
- Excess temperature in motors or hydraulic units.
- High noise during operation.
- Frequent hydraulic leaks.
- Unscheduled stoppages that always affect the same assembly.
According to data from the International Energy Agency (IEA), electric motors account for around 45% of global electricity consumption.
A badly designed machine consumes more energy, wears out more components and forces production to stop more often.
In projects where the problem lies in old hydraulic systems, many companies are opting for industrial electrification and electromechanical replacement solutions to reduce maintenance, leaks and energy consumption.
Mechanical redesign and FEM analysis to detect faults before manufacturing
One of the most common mistakes appears when parts are manufactured “by intuition”. Material is added where it seems necessary, thicknesses are increased or the assembly is oversized in the hope that it will last more years.
The problem is that this often produces machines that are slower, heavier and considerably less efficient.
That is why many industrial engineering firms now work with FEM (Finite Element Method) simulation. This system makes it possible to visualise stresses, deformation, fatigue or vibration before a single part is manufactured.
FEM validation helps detect:
- Structural fatigue points.
- Stress concentrations.
- Unwanted flexing.
- Dynamic problems.
- Thermal deformation.
- Mechanical resonances.
At Kernova, static, dynamic, harmonic and transient simulations are used to validate industrial machinery and redesign critical components.
A small vibration can end up breaking an entire line.
Many companies discover through simulation that the problem was not the motor or the PLC, but an accumulated deformation in an apparently secondary structure.
Which parts are usually modified during an industrial mechanical redesign?
It depends on the type of machine and the sector, although some components appear constantly in industrial projects:
In heavy machinery, many improvements appear after replacing hydraulic systems with electromechanical drives.
The KRN-H Series systems developed by Kernova are part of the Smart Eco-Motion Kit solutions, used to replace hydraulic cylinders in high-tonnage machinery.
These solutions make it possible to work with loads above 300 tonnes and strokes above 4 metres.
How mechanical redesign affects energy consumption
Some industrial machines consume energy even when they are not really producing. Hydraulic pumps running for hours, thermal losses or oversized systems generate an enormous expense at the end of the year.
Many factories discover too late that the problem was not the price of electricity, but how the machine was designed.
A well-planned mechanical redesign reduces:
- Friction losses.
- No-load consumption.
- The need for cooling.
- Unnecessary stresses.
- Current peaks.
- Hydraulic overpressure.
In industrial electromechanical systems, energy savings can exceed 35% depending on the application.
In addition, the efficiency of these systems usually exceeds 80%, compared with figures close to 60% in traditional hydraulics.
Less hydraulics means less oil, fewer leaks and less corrective maintenance.
Many installations also reduce noise, temperature and space occupied.
Is it worth redesigning old machinery?
Often yes. And considerably more often than some plants imagine.
There are industrial lines built 15 or 20 years ago with structures that are still sound, even though they mount old hydraulic systems, inefficient transmissions or discontinued components.
Replacing the whole machine can mean hundreds of thousands of euros and months of adaptation.
Mechanical redesign makes it possible to keep most of the installation and modify only the problem assemblies.
In many industrial projects, modernisation is carried out through electrification of hydraulic machinery solutions, keeping the main structure and replacing only the most problematic systems.
Besides the energy savings, other quite visible improvements appear:
- Less noise in the plant.
- Greater movement precision.
- Less dependence on ambient temperature.
- Reduced space occupied.
- Less corrective maintenance.
- Greater operational safety.
The electromechanical systems developed by Kernova work with precision of up to ±0.1 mm and cut installation space by more than 30% compared with traditional solutions.
Which industrial sectors are betting most on mechanical redesign
The trend is growing above all in industries where production stoppages cause high losses.
Currently standing out:
- Industrial recycling.
- Agro-industry.
- High-tonnage presses.
- Injection moulding machinery.
- Lifting and building maintenance equipment.
- Heavy industry.
In many cases, energy pressure and rising maintenance are accelerating these decisions.
There are factories that used to change hydraulic oil constantly and now work almost exclusively with scheduled greasing tasks.
Frequently asked questions
How long can a mechanical redesign project take?
It depends on the size of the machine and the modifications needed. Some partial projects can be completed in a few weeks.
Do you need to replace the whole machine?
No. Structures, frames and part of the original system are often kept.
Does FEM analysis avoid physical testing?
It reduces many of the errors before manufacturing and cuts iterations, although final validations are still necessary.
