---
title: "KOCH Pac-Systeme: Condition Monitoring with cynapse® | WITTENSTEIN"
url: "https://www.wittenstein-group.com/en-se/success-stories/koch-pac-systeme"
description: See how KOCH Pac-Systeme uses gearboxes with cynapse® and Smart Services to detect bearing damage early and prevent costly production downtime. Learn more.
date: 2026-09-28
modified: 2026-11-10
categories:
- Mechanical Engineering
- Packaging
---
# KOCH Pac-Systeme: Condition Monitoring with cynapse® | WITTENSTEIN
KOCH Pac-Systeme – Gearboxes with cynapse® prevent production downtime
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Identify potential damage risks early with digital condition monitoring
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By using gearboxes with cynapse® functionality and Smart Services from WITTENSTEIN alpha as the technological basis for KOCH Pac-Systeme’s digital service solution, ‘Predictive Pack’, a customer’s packaging line was able to detect incipient bearing damage at an early stage. This prevented millions in production downtime for the customer.
Predictive Pack with cynapse® Monitor
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With its Predictive Pack service product, KOCH Pac-Systeme offers a solution for the continuous digital monitoring of drive trains and associated components. The technological foundation consists of gearboxes from WITTENSTEIN alpha with integrated cynapse® functionality, as well as Smart Services built upon this. In a packaging system from the KBS-KF series for packaging button-cell batteries, scheduled for delivery at the end of 2023, several gearboxes with integrated sensor technology, logic, and an IO-Link data interface will be used.
The combination of cynapse® and Smart Services enables transparent, continuous condition monitoring of the entire drivetrain. Critical changes – such as in vibrations, temperatures, or speeds – are detected early on. This helps prevent unplanned machine downtime and address potential damage risks in a timely manner.
> The integration of gearboxes equipped with cynapse®, in combination with the Smart Service cynapse® Monitor, into the Predictive Pack enables continuous monitoring of the drivetrain and associated components.
Simon Brehmer, Head of Technology & Digitalization, KOCH Pac‑Systeme
Threshold monitoring detects bearing damage and prevents production downtime
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In this specific application, a TP+ 050 planetary gearbox with cynapse® from the alpha Advanced Line is installed in the drive system of of the die-cutting station. The data from this gearbox is analyzed by the Smart Service cynapse® Monitor. Using the threshold monitoring function, individual thresholds were automatically determined via teach-in after initial commissioning, jointly verified, and continuously monitored.
After a defined vibration threshold was exceeded, incipient bearing damage on the vertical stroke of the die-cutting station was identified and rectified. Had the damage gone undetected, the approximately two-week replacement time for the machine unit would have resulted in a production loss of around 20 million packaged batteries. The Predictive Pack saved the customer from a production shutdown costing millions.
Our products in use at KOCH Pac-Systeme
TP+
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The TP+ 050 planetary gearbox with cynapse® features integrated sensor technology, logic, and standardized IO-Link data output. It continuously provides data on operating hours, temperature, vibrations, and other condition parameters directly from the drive train. This data forms the basis for digital condition monitoring in the Predictive Pack from KOCH Pac-Systeme.
[ To TP+](https://www.wittenstein-group.com/en-se/product/tp)
cynapse®
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The the Smart Service cynapse® Monitor enables the visualization and analysis of data provided by the smart gearbox. Custom-defined thresholds and alarm notifications allow critical operating conditions to be detected early on. This provides transparency regarding the condition of the system and plays a key role in preventing unplanned machine downtime.
[ Explore cynapse®](https://www.wittenstein-group.com/en-se/product/cynapse)
TP+
cynapse®
Contact us
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