Hellweg Maschinenbau: “Smart Cut Guard” expands condition monitoring for granulators

The vibrations recorded by the new Smart Cut Guard module in Hellweg granulators provide insights into the condition of the machines - (Photo: Hellweg Maschinenbau).

Hellweg Maschinenbau GmbH & Co. KG will present its new “Smart Cut Guard” module at Fakuma 2026. The optional extension for the “Smart Control” control system uses a sensor to record vibrations in the granulator and analyze changes in vibration behavior. This is designed to detect worn blades or damaged bearings, among other issues, before major damage occurs. Based on the condition data, operators can adjust maintenance intervals and plan repairs at an early stage.

Vibration monitoring can be integrated directly into “Smart Control”. Alternatively, an additional module can automatically transmit the measurement data to a cloud service accessible exclusively to Hellweg. If unusual readings are detected, the machine manufacturer can contact the operator. This option is particularly intended for granulators that process large quantities of material in continuous operation.

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According to the company, the low baseline vibration levels of its machines make it easier to detect deviations. Hellweg attributes this partly to their heavy-duty construction and to rotors manufactured from a single solid blank, which have a high flywheel mass.

Additional modules for process monitoring
In addition to the new development, Hellweg will showcase the “Smart Sonic” and “Smart Flow” modules at Fakuma 2026. “Smart Sonic” uses ultrasound to measure material flow, providing the basis for demand-based feeding. “Smart Flow”, first presented at K 2025, uses a microwave sensor to measure the bulk material flow in the vertical pipe of the extraction system without contact. This is intended to enable the actual granulation throughput to be determined.

The basic “Smart Control” system monitors the size reduction process and adjusts the granulator's output to demand. Together, the three additional modules provide information on material feed, throughput and machine condition. The data collection is intended to help coordinate energy consumption and granulation performance while enabling condition-based maintenance planning. The company does not provide specific performance figures or potential savings.

Fakuma 2026
Friedrichshafen, Germany
12–16 October 2026
Hall A1, Stand 1005

More information: www.hellweg-granulators.com/en

Hellweg Maschinenbau GmbH & Co. KG, Roetgen, Germany

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