Battenfeld Unilog 4000 refit: controller replacement for plastics processing
Wittmann supports only machines built after 2008 (the Wittmann Battenfeld line). Pre-2008 Battenfeld machines with Unilog 4000 controls are orphan systems without manufacturer support.
Battenfeld Maschinenfabrik went bankrupt in 2008 and was acquired by Wittmann. Hundreds of pre-2008 machines now run as orphan systems without OEM support. GCG replaces the Unilog 4000 controller with a modern B&R X20 installation, preserving recipes, cycle times and CE conformity.
Battenfeld & Unilog series
| Controller | Era | Status |
|---|---|---|
| Unilog B2 / B4 | 1985-1995 | Fully EOL, no parts |
| Unilog 4000 | 1992-2008 | EOL, SRAM battery critical after 15-20 years |
| Unilog B6 | 1998-2008 | EOL, limited parts via Wittmann |
| Unilog B8 / B8X | 2008-heden | Actively supported by Wittmann |
Unilog 4000 architecture: what you need to know
Platform: Motorola 68000
Closed, proprietary real-time OS. Incompatible with modern tools. Software modification by third parties is practically impossible without Battenfeld source code.
SRAM battery: critical risk
All machine recipes and calibrations are stored in battery-backed SRAM. After 15-20 years battery failure is a real risk. GCG always performs a parameter dump via the serial port before migration.
Communication: RS-485 proprietary
The Unilog 4000 communicates via a proprietary RS-485 variant. Later versions support Euromap 63. When migrating to B&R X20, the new platform supports Euromap 67/77 out of the box.
I/O mapping: manual work
There is no automated conversion path from Unilog 4000 to B&R. GCG performs a full wiring audit and rebuilds the application programme from the original wiring diagrams and machine behaviour specifications.
Polish installed base: why now?
Poland has one of the largest concentrations of pre-2008 Battenfeld machines outside Germany and Austria. The machines were purchased during the economic growth phase of the 1990s and early 2000s. They are still running, but the controllers are approaching the end of their functional service life.
From Unilog 4000 to B&R X20
B&R X20 / Automation Studio + Euromap 67/77 + mapp View HMI
Parameter dump
Read out all recipes and calibrations via the serial port before the machine is stopped.
Wiring audit
Full inventory of sensors, actuators, safety switches and fieldbus couplings.
B&R engineering & FAT
Build application programme in Automation Studio, prepare cabinet, FAT at our workshop in Eindhoven.
SAT & moulding qualification
Commissioning on the production floor, 5 reference products for qualification, operators trained. Average downtime: 48-72 hours.
3-5 machines together: 20-35% cost reduction
GCG offers Polish injection moulders a cohort approach: 3-5 companies with similar Battenfeld machines clustered into a 6-12 month migration programme. The B&R base application for an HM series is developed once and reused for all machines in the cohort. This significantly reduces engineering costs.
Register for next cohort →Frequently asked questions
Can my Unilog 4000 be repaired?
In theory yes, but parts availability is declining rapidly. The Motorola 68000 processor and SRAM battery are the critical components. GCG recommends migration when alternative parts are no longer available or when the battery has already been replaced.
Are my machine recipes preserved after migration?
Yes, provided the parameters are read out via the serial port before migration. GCG always performs a parameter dump as the first step. In rare cases where the SRAM battery has already failed, recipes are lost; we can then set new parameters based on process data and production samples.
Does the machine run during the refit?
No, downtime is 48-72 hours for a standard Battenfeld HM/TM machine. Engineering and cabinet preparation take place in advance. GCG schedules the downtime in a planned maintenance window to minimise production loss.
What does a Battenfeld Unilog 4000 refit cost?
Costs depend heavily on machine configuration, number of I/O points, presence of an F-safety PLC and HMI language requirements. An indicative range for a single Battenfeld HM series: EUR 18,000-35,000. For a cohort of 3-5 similar machines this drops by 20-35%.