Flexibly Automated: How Ernst Reiner Uses Robotics to Future-Proof Manufacturing

Ernst Reiner is a company with both history and vision. Family-owned for three generations, it all started with the production of stamps—a product still widely used today by customs offices and government agencies around the world. But Ernst Reiner is far more than a stamp manufacturer. Under the umbrella of Ernst Reiner GmbH & Co. KG, the company develops mobile marking systems and scanners. In its Precision Engineering division, it offers a wide range of manufacturing technologies for external customers.

With around 200 employees at its location in Furtwangen, Germany, Ernst Reiner is deeply rooted in the region. Apprenticeships and dual-study programs are highly valued—just like the continuous advancement of manufacturing technologies. In the Precision Engineering division, which operates as an independent business unit, medium-sized production runs of 1,000 to 100,000 parts per year are manufactured.

In sheet metal processing, all relevant processes are covered—from stamping and laser cutting to bending and welding. High-precision machining is also offered, along with the production of injection-molded, die-cast, or MIM (Metal Injection Molding) parts. Customers typically come from industries that either lack their own production facilities or do not have the necessary expertise, experience, or capacity for certain processes.

“We offer everything from a single source—from individual parts to ready-to-install assemblies,” explains Marco Rombach, Head of Tool Design at Ernst Reiner. “Our strength lies in the variety of technologies and the high level of vertical integration.”

Endüstriler
Kimya ve Plastik Endüstrisi Çözümleri

uygulamalar
Machine Tending

müşteri
EGS Automation GmbH

Ürünler
GP Serisi

Picture: The Yaskawa GP12 during machine loading. When moved to its rest position, there is enough space in front of the machine for setup operations and manual loading/unloading of small batches.

Why Automation—and Why EGS?

Automation is nothing new at Ernst Reiner. In the past, the company developed its own automation solutions for series production of stamps and printers in its in-house toolmaking department. However, as batch sizes decreased and product variety increased, this concept reached its limits. About five years ago, the need arose for flexible, robust, and efficient automation in the precision sector.

“The shortage of skilled workers was a driver, but so was the desire for unmanned shifts and stable processes,” says Patrick Wolff, Head of Sheet Metal Production. “We wanted a solution that adapts to our requirements—not the other way around.”

After extensive market research and recommendations from the personal and professional networks of the involved employees, the choice fell on EGS Automation. Geographic proximity, technical expertise, and a collaborative partnership were decisive factors.

Picture: The robot loads and unloads the machining center in parallel with main time. Before loading, the robot cleans the workpiece fixtures.

Innovation & Agility

EGS Automation designs customized, highly flexible special-purpose systems that adapt quickly to changing processes—powered by decades of robotics expertise and cross-industry experience that set us apart from the competition.

EGS Automation, based in Donaueschingen, has nearly 30 years of experience in robotic automation. The company offers a wide range of standard solutions and has also made a name for itself through its expertise in implementing custom solutions—particularly in the automation of machine tools and injection molding processes. The combination of technical depth and practical implementation makes EGS a sought-after partner for mid-sized manufacturing companies.

Picture: The second and third identical systems are positioned side by side. This arrangement ensures minimal personnel involvement.

First Robotic Cell: A Milestone

The first robotic cell at Ernst Reiner was connected to an existing Chiron FZ15W CNC machining center, which had previously been loaded manually. The machine’s rotary table is loaded and unloaded on one side, while workpieces are machined on the other. The space-saving layout of the EGS cell was immediately convincing—a key factor given limited production space. EGS positioned the robot so that manual loading remains possible, for example, for small batches or during setup. Retrofitting the existing machine for automation—such as converting manual clamping devices to automatic clamping technology—turned out to be more complex than initially expected.

“That was an important learning curve,” recalls Marco Rombach. “But the integration of the robotic technology itself went surprisingly smoothly. Our employees quickly got the hang of it—thanks in part to EGS Automation’s hands-on training.”

Picture: The robot’s dual-gripper tool is optimized for all gripping positions in the process and allows fast workpiece changes at every station.

End-to-End & Reliability

As your end-to-end partner, EGS develops tailored special-purpose systems from concept to maintenance; our proven robotics know-how and multi-industry experience ensure fast commissioning, sustainable results, and a clear competitive edge.

The robotic system designed by EGS Automation fully automates the loading and unloading of a machining center. Workpieces are always processed in pairs. The robot removes raw parts one by one from the workpiece carriers and precisely aligns them on a regrip station. The parts are then temporarily placed on an intermediate shelf.

Before a new raw workpiece is inserted, the robot first removes the finished part from the clamping fixture. To ensure a reliable handover, both the finished part and the clamping fixture are cleaned of chips and coolant using compressed air. The robot-guided air nozzle ensures thorough cleaning from all sides and within complex workpiece geometries. Afterward, the raw part is picked up from the intermediate shelf and inserted into the fixture.

This process is repeated for the second workpiece. After loading is complete, the robot waits for the next machine cycle until the rotary table switches again and the sequence starts over.

Fast and precise workpiece handling is performed by a Yaskawa GP12—a 6-axis articulated robot with a reach of nearly 1.5 meters and a payload capacity of 12 kilograms.

Picture: The SUMO Ecoplex2 can be loaded in automatic mode through its two front doors using floor rollers stacked with workpiece carriers.

Scaling Up Automation

“EGS didn’t just deliver a solution—they empowered us to think further,” says Patrick Wolff. “We’ve since purchased our own robot for experimental setups to build internal expertise. EGS supports us when needed—without any protectionism.”

The next automation solution is already in the works: a robotic cell for injection molding. Here, hybrid components will be manufactured automatically. From the precise positioning of insert parts, to loading and unloading, inspection, and packaging of finished components—the entire process around the injection molding machine will be fully automated.

Ernst Reiner is very satisfied with the Yaskawa robots in use: “Reliable, fast, and compact,” summarizes Marco Rombach.

Productivity & ROI

With EGS, you gain cost-effective special-purpose solutions that deliver measurable improvements in productivity, quality, and efficiency—built on more than 2,300 installed robots and proven best practices across metal, plastics, and assembly applications.

Automation at Ernst Reiner is not an end in itself, but part of a clear strategy: to relieve skilled workers, stabilize processes, and secure competitiveness with modern and reliable manufacturing technology. The combination of technical expertise, regional roots, and a collaborative partnership with EGS Automation has proven to be a recipe for success.

Author: Heiko Röhrig; Senior Business Development Manager bei EGS Automation

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