K 4.0 smartpacks


The potential for added value must be recognized and tapped. To meet this standard, we have put together perfectly matched digital service packages which are individually applicable to your customer requirements. The K 4.0 smartpacks stand for more productivity, increased availability and optimized overall equipment effectiveness. The reduction of unplanned downtimes and the permanent reduction of maintenance costs are particularly important to us.

All KOCH digital services are based on the unique, innovative, and awarded HMI control system. The system was awarded with the coveted Red Dot Award in 2019 for the outstanding development of the "easyControl" concept and guarantees excellent user-friendliness throughout the entire operating process.


  • Faster error diagnosis – up to 50 %
  • Faster machine setup – up to 10 %
  • User interface customizable
  • Creation of extended user groups
  • User administration via directory service Active Directory
  • Full machine integration into the IT infrastructure
  • Cross-machine administration of product formats
  • Step and cycle sequence for stations:
    Additional operating modes for noticeably accelerated error diagnosis and faster machine setup
  • WLAN access point including mobile device (tablet):
    Location-independent visualization of machine functions via mobile device – available where the information is needed


  • Avoid machine downtimes
  • Early recognition of optimization potential
  • Overview of all production figures
  • Improved packaging quality
  • Predictive maintenance for wearing parts such as gears, vacuum systems, motors, and pneumatic components
  • Continuous performance monitoring of the individual machine parts by visualizing station performance
  • Analysis of operating data over a defined period (e.g., production, downtime, setup, and error evaluation)
  • Monitoring of process-relevant functions and data
  • I/O diagnosis reading      
  • Consumption reading and monitoring of pressure, flow, and utilities consumption, as well as overall energy consumption of the machine
  • Intelligent electrical components for the recording of energy consumption, flow measurement, including diagnosable 24 V current circuits


  • Easy, monitored data access
  • Link to higher ranking systems
  • Compliance with security standards of the National Institute of Standards and Technology
  • Use of TLS certificate and x.509 for secure data transmission
  • Highly secure SSL/TLS connection between KOCH Smart Analytics System (cloud system) and customer to acquire machine wear and condition data
  • OPC UA server as universal interface to access data on process variables
  • Order management and monitoring via standard interfaces to ERP/PPS/MES/SCADA systems


  • Maximization of machine potential
  • Overview of the entire production process
  • Diverse analysis and visualization options

KOCH Smart Analytics Dashboard

  • Web-based system with secure access
  • Monitoring of the entire machine
  • Full transparency regarding availability, performance, and quality
  • Fast analysis of stop causes, downtimes, and performance
  • Helpful production trends, times, and counter readings at a glance
  • Operation assessment and easy recognition of improvement potential
  • Condition monitoring of wearing parts
  • Detailed analysis of station performance

Additionally required: Connectivity Pack and Predictive Pack


  • Lower energy costs – up to 20 %
  • Monitoring of consumption figures
  • Intelligent drive management with regulated drive power and speeds according to the desired machine performance
  • Display of electric and pneumatic energy consumption on the user interface
  • Eco operating mode for improved and eco-friendly machine performance
  • Time switch and energy-saving functions for production breaks and shift changeovers


  • Compliance with statutory regulations governing medical devices

Full machine monitoring in compliance with GMP and 21 CFR Part 11 requirements:

  • Logging of all process-relevant parameters and values
  • Logging of all machine conditions and error reports
  • Data security and system protection against manipulation
  • Restricted access with extended user authentication
  • Two-person control and signature verification in the case of system modifications
  • IPC-computer is included

Additionally required: Usability Pack


  • Central planning of production batches
  • Optimum machine utilization

Batch Management und Reporting

  • Full planning of production lots and batches
  • Batch Reporting after completion of a batch

Central formula management

  • Central retention of format and production data
  • OPC UA Server Lizenz


  • Straightforward and customized training package 4.0
  • Instruction for new operators in short, coherent, and easy-to-grasp units
  • Digital and location-independent
  • Straightforward, clear animations and video snapshots for operator guidance and training purposes
  • Fast, individual access to operating instructions, spare parts management, and circuit diagram via the user interface
  • Online electrical and fluid circuit diagrams integrated into the user interface


  • Personal problem analysis within 24 hours
  • Smart support worldwide
  • Services with added value
  • First problem analysis on site within 24 hours by a service technician from Germany, the USA, or Singapore
  • Premium hotline 24/5: “Follow-the-sun“ support by forwarding inquiries to the respectively available locations in Germany, the USA, or Singapore
  • Personal contact for advice on the management process over the entire product lifecycle
  • Virtual three-day instruction on machine basics and maintenance
  • Servicing once a year
  • Individual advice on professional spare parts management:
    Discounts on spare parts according to a defined discount scaling
  • Starter kit: tool trolley with basic supply of lubricants and tools

--> Best customer benefit, if ordered in combination with Predictive Pack