Design software
Special plant manufacturer develops complex designs
Mechtop in the north of Switzerland builds special machines and systems. Solid Edge and Tecnomatix from Siemens help to design and maintain sophisticated conveyor systems. By Peter Kemptner
Founded in 1995 as a maintenance service provider for industrial machinery, the company now designs and produces customized steel structures, tanks and apparatus as well as piping and conveyor systems. Mechtop's 55 design engineers, fitters and production staff cover the entire development and manufacturing process through to commissioning and offer maintenance services throughout the entire system life cycle.
The motto "Mechanics in Motion" not only describes Mechtop's dynamic, agile and forward-looking approach to metal construction, it also stands for the company's highly developed conveyor technology. Developed over decades at a specialist company acquired in 2016, it is now a cornerstone of Mechtop's business. Working closely with customers, eight project managers create conveyor systems primarily for the food industry.
Solid Edge for construction
The engineers at Mechtop use Solid Edge software from Siemens Digital Industries Software to design the special systems. "This 3D CAD software supports users and is easy to learn; new colleagues need little training," says Jürg Bachmann, Head of Technology and Production, Mechtop. "At the same time, it has everything we need to create and check our large and often highly complex designs, including powerful sheet metal and piping functions."
Mechtop engineers used Solid Edge to design a customized conveyor system for a leading food chain. Arranged around a central cleaning machine, it includes a stacker and an unstacker for the food crates and a buffer zone for cleaned containers that are not needed immediately. The system is designed for 2,000 crates per hour, which corresponds to one crate every 1.8 seconds. A system downtime of just 30 minutes could result in a shortage of containers in one of the food retailer's branches the next day.
Given these framework conditions, it came as no surprise that the customer demanded a proof of concept before placing the order worth around CHF 3 million. "With Solid Edge, we can only show the customer 3D models," says Bachmann. "To convince a customer that the system will meet their requirements, you need a digital twin with time behavior."
Material flow optimization with Tecnomatix
In search of the right software solution, Bachmann turned to Cytrus, a solution partner of Siemens Digital Industries Software with three locations in Switzerland, one each in the German-, French- and Italian-speaking parts of the country. Cytrus Plant Simulation recommended a solution for digital production from Siemens' Tecnomatix® portfolio for setting up digital twins of logistics systems and processes.
Robin Vornholt is a Senior Consultant at Cytrus, the only Siemens Smart Expert for this software in Switzerland. "With Tecnomatix Plant Simulation, users can model, simulate, examine and optimize systems and processes related to material flows," he explains. "Using discrete event simulation and statistical analysis, these digital images enable analysis and optimization of material flow and resource utilization long before production begins."
After three days of training by Cytrus, three Mechtop employees created a simulation model of the conveyor system for the container cleaning process. "We had to adhere to a very tight schedule," comments Bachmann. "The biggest challenge was to provide proof of concept for the denester within two weeks."
The simulation results convinced the customer that the system offered by Mechtop would meet all requirements. After receiving approval, the engineers developed the digital twin of the cleaning system in less than two months. Supported by Cytrus' plant simulation experts, they created a library of models of their conveyor products. To create the models, they imported data from Solid Edge in the Siemens JTTM file format and used information on time behavior from Excel spreadsheets.
"Plant Simulation has an object-oriented, hierarchical structure," says Bachmann. "With this software, 2D/3D models of complex, dynamic layouts can be created quickly and intuitively."
Early design review
Plant Simulation also makes it possible to illustrate simulation results with diagrams and interactive 2D/3D real-time visualization. Mechtop uses this software capability to optimize system parameters and for planning. However, Plant Simulation's comprehensive simulation and visualization tools are mainly used in sales, as they allow meaningful presentations to be created on the basis of valid design data.
"Plant Simulation enables project visualization in the earliest project phases," says Bachmann. "With simulation-based material flow optimization, we can offer our customers added value and ensure the success of their projects."
Box: Digital twin
Digital twins create the link between the physical and virtual worlds and are therefore the key to the digital factory. The digital twin is a digital replica of products, processes, systems and physical objects. It gives companies of all sizes new insights, opportunities and degrees of automation to drive innovation and significantly increase efficiency and performance levels. For this to succeed, each digital twin must be customized to the requirements of its environment. Siemens Digital Industries Software supports companies with the integrated Xcelerator portfolio of software for design, engineering and manufacturing on a unified platform.
By Peter Kemptner, freelance journalist
You might also be interested in
Robotics and autonomous order picking
Locus Robotics acquires Nexera Robotics and expands autonomous warehouse logistics
Locus Robotics takes over Nexera Robotics and may have taken a decisive step towards truly universal warehouse automation. A new gripping technology should now make possible what was previously considered difficult to automate.
read more...How bridging steps, stairs and catwalks are changing processes in production and logistics
At Logimat 2026, Munk Günzburger Steigtechnik will be showcasing modular bridging steps, stairs, platform and walkway systems for production, warehousing and logistics. With online configurators, distances can be efficiently shortened, processes...
read more...Highly automated warehouse for...
SSI Schaefer implements highly automated warehouse for CERP in France
SSI Schaefer and CERP are building a highly automated logistics center for pharmaceutical logistics in Wissous with shuttle storage, A-Frame, robotics and WAMAS software.
read more...Start of construction for new production hall
Mayr Antriebstechnik invests in its home base and internationally
Mayr Antriebstechnik strengthens location and international logistics: Construction of a new hall in Mauerstetten - parallel expansion of the plant in Poland as a logistics hub.
read more...Conveyor systems that adapt
Modern conveyor systems must reliably transport different product sizes, shapes and materials. The new modular product system from Kipp offers flexible, modular solutions for this: Adjustable side guides ensure precise alignment and gentle...
read more...Focus on sustainability and AI at the trade fair
With more than 120,000 square meters of exhibition space, LogiMAT 2025 will once again occupy all ten halls of the Stuttgart exhibition grounds. From March 11 to 13, global players, medium-sized companies and start-ups will provide an overview of...
read more...Workstation system for shipping and logistics
With Sintro Packing, Karl is launching a workstation system that is designed to meet the specific requirements of shipping and logistics. It is characterized by modular adaptability and ergonomic efficiency.
read more...Deutsche Messe announces Robotics Award
On the occasion of Hannover Messe 2025, Deutsche Messe is once again presenting the Robotics Award after a break of several years. Prizes will be awarded for robot-supported automation and logistics solutions. Companies and institutions from Germany...
read more...Micro motors as the driving force behind intralogistics
Suitable transport structures in intralogistics are a prerequisite in all industries in order to withstand competitive pressure in the future. The basis for this is comprehensive automation, which would be inconceivable without an armada of powerful...
read more...