Ferromatik Milacron refit: controller replacement for hydraulic and all-electric machines
After the Chapter 11 restructuring in 2009 and acquisition by Hillenbrand, Ferromatik Milacron was sold to Bain Capital in 2025. The European support network for legacy K-TEC and Elektra machines has been unstable since. GCG provides an independent migration route that does not depend on the current ownership structure of Ferromatik.
Ferromatik Milacron went through a Chapter 11 bankruptcy in 2009. After acquisition by Hillenbrand and sale to Bain Capital (2025), legacy support for K-TEC and Elektra machines in Europe is uncertain. GCG analyses your machine generation, hydraulic K-TEC or Fanuc Roboshot, and delivers a tailored migration plan to B&R X20 preserving all recipes and CE conformity.
Ferromatik Milacron series: lifecycle and support
| Machine | Era | Status |
|---|---|---|
| K-TEC / KM (hydraulisch) | ~1990-2006 | EOL: Ferromatik NC control no parts available |
| Elektra (all-electric) | ~1995-2005 | EOL: hybrid Fanuc architecture, limited support |
| Delta (all-electric) | 2000-2009 | EOL: Fanuc Roboshot architecture, ownership changes |
| Roboshot (all-electric) | 2003-heden | Active, but support uncertain after sale to Bain (2025) |
K-TEC vs Roboshot: two migration paths
K-TEC NC control: standard migration
The K-TEC uses a Ferromatik proprietary NC control on S5-era hardware. This is a standard migration path: wiring audit, parameter dump via serial port, B&R X20 engineering, FAT, SAT. Comparable to Battenfeld Unilog or Demag NC4.
Roboshot / Delta: Fanuc-locked
The Roboshot and Delta are all-electric machines with a Fanuc servo architecture. The Fanuc servo controller (series 30i/31i) is deeply integrated with the machine protocol. GCG first performs a bespoke analysis to determine whether the servo layer can be retained or must be replaced.
Ownership history: support risk
Malterdingen (1950s) → Milacron (US) acquisition → Chapter 11 (2009) → Hillenbrand (2013) → Bain Capital (2025). Each ownership change has further thinned legacy support for pre-2009 machines. GCG provides independent migration without dependence on Ferromatik.
I/O mapping: manual for all series
There is no automated conversion path for Ferromatik machines. GCG documents all signal routes via wiring audit and rebuilds the machine functionality on the target platform. For K-TEC machines this is typically 2-3 weeks of engineering.
German installed base: refit peak 2025-2030
Baden-Wurttemberg has the highest density of Ferromatik Milacron K-TEC machines in Europe, the home region of the Malterdingen plant. Machines from the period 1996-2006 are now 20-30 years old. The combination of ownership uncertainty at Ferromatik and the age of the controls makes 2025-2030 the critical migration window.
From Ferromatik NC to B&R X20: K-TEC route
Machine audit
Determine whether machine is hydraulic K-TEC or Fanuc Roboshot. Decision on migration strategy (standard B&R or bespoke).
Parameter dump & wiring audit
Read out recipes via serial port. Full inventory of sensors, actuators and safety architecture.
B&R engineering & FAT
Application programme in Automation Studio, prepare cabinet, FAT in Eindhoven. Documentation in German standard.
SAT & moulding qualification
Commissioning production floor, 5 reference products, operators trained. K-TEC downtime: 48-72 hours.
3-5 K-TEC machines together: 20-35% cost reduction
GCG offers a cohort approach for similar K-TEC machines: 3-5 companies clustered into a 6-12 month migration programme. The wiring structure and application logic of a K-TEC series are documented once and reused for all machines in the cohort. This is not possible for Roboshot machines due to the machine-specific Fanuc integration.
Register for next cohort →Frequently asked questions
Can my Ferromatik K-TEC be repaired?
Theoretically yes, but the NC control cards for the K-TEC have long been unavailable. Reconditioning of existing cards is the only option, but reconditioning specialists are becoming scarce. GCG recommends migration once a card fails a second time.
What is the difference for a refit between a K-TEC and a Roboshot?
The K-TEC is a hydraulic machine with a proprietary NC control, comparable to Demag NC4 or Battenfeld Unilog in migration strategy. The Roboshot is an all-electric machine with a Fanuc servo architecture deeply integrated with the servo control. For Roboshot, GCG recommends a bespoke analysis to determine whether the Fanuc servo layer can be retained.
Does the machine run during the refit?
No, downtime is 48-72 hours for a standard K-TEC hydraulic machine. For Roboshot machines with Fanuc replacement this can be 72-96 hours due to the more complex servo integration. GCG always plans in consultation with production scheduling.
What does a Ferromatik Milacron refit cost?
For K-TEC hydraulic machines: EUR 16,000-32,000 per machine (depending on I/O scope and safety architecture). For Roboshot/Delta all-electric machines a bespoke quotation is required because the Fanuc servo integration varies per machine. Cohort of 3-5 K-TEC machines: 20-35% cost reduction.