Precise, reliable, and flexible – completely automatic

With the continuous-motion rotary table systems from Contexo, users can efficiently produce mass products. (Photo: Contexo GmbH)

In family hands: The brothers Matthias, Jürgen, and Steffen Müller jointly run the company. (Photo: Contexo GmbH)

High-performance rotary indexing machine: The basis is a mechanical rotary table with pick-and-place units, driven by central cam discs. (Photo: Contexo GmbH)

The components are fed into the synchronized systems and isolated. (Photo: Contexo GmbH)

Contexo develops a wide variety of systems – for example, machines that produce and inspect painted plastic control elements. Subsequently, the components are placed into packaging blisters. (Photo: Contexo GmbH)

The rotary indexing machine for the assembly of plastic clips is designed for an output of 240 parts per minute. It is connected to a packaging unit. (Photo: Contexo GmbH)

The systems are equipped with high-performance feed devices. (Photo: Contexo GmbH)

For the installation of the systems, Contexo employees have approximately 2,000 square meters of space available. (Photo: Contexo GmbH)

Diagnostic cartridges for laboratories, push-pull closures for beverage cartons, desiccant stoppers that ensure a consistently dry climate in packaging: all of these must be assembled with utmost precision. Only then do they perform their function optimally. The more complex they are, the more process steps are required. The components need to be fed, assembled, printed, welded, glued, sealed, or laser-cut. Given the often very high quality requirements and batch sizes, automated systems are needed to integrate these steps and perform them accurately, reliably, economically, and flexibly. Contexo GmbH in Winterbach near Stuttgart is among the market leaders in developing and implementing efficient automation solutions. The goal of the family-run company is to tailor and execute each task perfectly and fairly. Contexo draws on almost 40 years of experience.

The family spirit, enthusiasm for innovation, and the extensive expertise of the employees distinguish Contexo GmbH. The range of offerings includes semi-automatic cells, rotary and linear cycle, as well as continuous motion systems for mass production. The systems are used in various industries, all sharing one requirement: products must be assembled with the utmost precision very quickly. Contexo has therefore specialized in machines with very high performance. "The components are no larger than about two fists," describes Jürgen Müller, who runs the company with his parents Heide and Karl, and his brothers Matthias and Steffen. "Our assembly systems mainly process plastics as material." Once the machines are completed and tested in Winterbach, they are shipped to customers worldwide. On-site, the systems are commissioned, and the operating and service personnel are trained. Contexo manufactures most systems as custom-made units specifically adapted to the respective tasks.

From ballpoint pens to medical syringes

In Winterbach in Swabia, Karl Müller founded a mechanical workshop in 1975 under the name Karl Müller Maschinenbau. He successfully manufactures metal bandsaws and precision parts. In the early 1980s, the company develops and sells its first automation and handling solutions. Under the name Müller & Kurtz GmbH, the company also develops and manufactures high-performance assembly and testing machines. Initially, machines are produced for the pen and cosmetics industries. "And from pen to medical syringe, the shape isn't that far apart," reports Jürgen Müller. This quickly made the young company known in the medical industry as well.

Turbulent Years

The businesses of Müller & Kurtz and Karl Müller Maschinenbau are doing well, and both companies are growing—until 2004: an export business in the Arab region collapses. The companies become insolvent through no fault of their own. In 2006, the Müller family seizes the opportunity to bring the company back into family hands and establishes Contexo GmbH from it.

Today, the company employs around 80 people and generates approximately 18 million euros in revenue annually. "The foundation of our success is not only the high-quality systems but also the close relationship with our customers," explains the managing director. In close collaboration with users, Contexo develops automation solutions that meet all requirements of modern factory and production automation: material flow, production, final inspections, and packaging solutions. The Contexo employees handle the entire project management—from machine conception to commissioning. Speed, adherence to deadlines, partnership, and reliability are standard for every project.

Home in many industries

"We are a reliable partner in various industries, whether for small systems or large projects," says Jürgen Müller. For medical technology, the automation engineer produces systems that quickly assemble complex products in high batch sizes. The compact systems, with six to 54 stations, consist of standardized modules that assemble, seal, punch, and inspect. Upon request, Contexo integrates additional technologies such as banding, labeling, dosing, and much more. Even with product changes or expansions, the systems remain flexible in the long term. They are also designed for cleanrooms of class 10,000 ISO/7 and can be used as special versions in lower cleanroom classes. Additionally, the production meets GMP (Good Manufacturing Practice) conditions. The FDA requirements, such as compliance with 21 CFR 11 for computer-controlled systems, are also implemented. The quality demands in the medical field include extensive documentation. Contexo GmbH provides this as a complete package (DQ, IQ, OQ) with protocol generation, testing, and results documentation upon request. Systems for medical products today generate more than half of Contexo's revenue.

The portfolio also includes assembly systems for diagnostic cartridges. These are highly complex and can consist of up to 100 individual parts. Special assembly processes and handling are required to produce them with high precision and reliability. Production steps include laser welding, ultrasonic welding, filling, stamping, labeling, and inspection. "For example, we built an almost fully automated assembly line, including qualification, for Curetis AG based in Holzgerlingen, Swabia," reports Jürgen Müller. "This company manufactures cartridges made of plastic for the molecular diagnosis of infectious diseases. The miniature laboratory is the most complex of its kind worldwide."

Another major application area is linear cycle machines for assembling dosing and spray pumps—for example, for the cosmetics industry. These can consist of a variety of parts (currently up to 20). The machines are also used by customers who need to quickly and efficiently assemble brushes for mascara, perfume bottles, soap pumps, or aerators for faucets.

An important market is also multi-part beverage closures for carton packaging, such as milk and juice cartons, as well as PET bottles with push-pull closures. Contexo supplies an advanced high-performance system capable of assembling three-, four-, and five-part caps at a cycle rate of 1,000 parts per minute. Depending on the requirements, the machines also check for tightness or perform other customer-specific quality controls.

"Without our motivated and highly qualified staff, we could not produce these innovative systems," Jürgen Müller is confident. For the family-run company, employees are the most valuable asset. Contexo places great importance on continuous training. The special machinery manufacturer offers an extensive training program for young people. Every year, several youths start their apprenticeships at Contexo. The goal is always to grow together and steadily. "Against this background, we as system providers can always meet the individual wishes of our customers and the demands of the market," promises the managing director.