Smart Hydraulics in Spark Plug Production
Discover how Bosch’s cutting-edge Bamberg production plant harnesses Rexroth’s CytroBox for improved efficiency and sustainability.
The Bosch plant in Bamberg manufactures spark plugs using state-of-the-art hydraulics. An upgrade with the stand-alone CytroBox power unit increases productivity and reduces energy consumption by over 50 percent, marking a significant step in sustainable industrial manufacturing.
120 years of innovation meets the future of hydraulics
More than a century ago, the first spark plug revolutionised automotive engineering. Today, Bosch’s Bamberg plant continues this tradition of innovation, producing spark plugs for the global market using cutting-edge technologies. As a facility heavily focused on reducing its emissions and impact on the environment, Bosch prioritises energy efficiency and process reliability. This commitment extends to industrial hydraulics, where sustainability and intelligence go hand in hand.
A smarter approach to hydraulic power
A recent modernisation effort aimed at increasing energy efficiency targeted six Panat presses in a high-speed production line. These presses handle conductive glass filling and press it under high pressure (135 bar) into the ceramic housing of spark plugs. To accommodate product expansion requiring longer spark plug types, the facility upgraded its hydraulic power units. Rather than relying on traditional assemblies with large hydraulic accumulators, Bosch adopted Rexroth’s intelligent stand-alone CytroBox solution.
Seamless integration with immediate benefits
Unlike conventional hydraulic units, the CytroBox is compact, quiet and equipped with smart technology. Because it eliminates the need for additional electrical installation, external sensors, sound insulation, or separate oil sumps, its installation is significantly more straightforward. Once power supply, hydraulic hoses, and line control are connected, a software wizard guides setup within minutes. This ease of integration accelerated the transition at the Bamberg plant, minimising downtime while maximising efficiency gains.
Smart pressure supply for enhanced quality and reliability
At the Bosch plant in Bamberg, the CytroBox has successfully provided a process-reliable and intelligent pressure supply while reducing the unit’s footprint by 50 percent. The finely controllable electrohydraulics ensure precise pressure regulation with rapid buildup, preventing overshoots and system overloads. This precise control enhances product quality and improves overall process stability.
Advanced digitalisation and predictive maintenance
A key advantage of the CytroBox is its modular design, which allows for easy customisation with safety functions such as emergency stop and integrated monitoring. Standardised interfaces facilitate seamless line integration, ensuring smooth operations. Additionally, the CytroBox’s connectivity aligns with modern manufacturing requirements, offering built-in technology for condition monitoring and predictive maintenance. By collecting and analysing real-time data, Bosch can proactively address maintenance needs, preventing unexpected downtime and optimising production efficiency.
59% reduction in energy consumption and CO2 emissions
The flow-optimised design of the CytroBox and its variable-speed drive, operating on an energy-on-demand principle have reduced electricity consumption at the plant by 59 percent. This efficiency is driven by precise displacement control, which generates hydraulic pressure only when required, shifting into energy-saving standby mode otherwise. This innovation contributes significantly to Bosch’s sustainability goals. Furthermore, the CytroBox’s advanced servo motor, high-efficiency pump, and 3D-printed hydraulic block work in harmony to create an ultra-quiet unit, enhancing workplace comfort.
A blueprint for future hydraulic modernisation
The CytroBox, part of Bosch Rexroth’s Connected Hydraulics portfolio, has proven to be a reliable and innovative solution. According to Group Leader Daniel Link, the unit operates so seamlessly that its presence is hardly noticed—perhaps the highest compliment a production manager can give a hydraulic system. Encouraged by this success, Bosch plans to expand modernization efforts to additional production lines, including those with compact hydraulic units, further solidifying its commitment to low-carbon, fully networked manufacturing.
Expanding intelligent hydraulics for greater productivity
Building on the success of the CytroBox, Bosch is exploring further enhancements to its production infrastructure. Integrating more intelligent hydraulic systems across multiple production lines will provide even greater control, reliability, and efficiency. The ability to dynamically adjust hydraulic pressure in real-time will allow Bosch to optimize production cycles and reduce wear on critical components, extending equipment life while maintaining high product quality.
Moreover, the seamless scalability of Rexroth’s Connected Hydraulics solutions means that Bosch can easily adapt to future demands. Whether increasing output capacity or integrating with next-generation automation systems, the CytroBox and similar technologies provide a robust foundation for ongoing innovation.
A commitment to sustainable and smart manufacturing
As the company continues to refine its production processes, it remains focused on leveraging cutting-edge technology to enhance productivity while maintaining environmental stewardship. This commitment is exemplified through its collaboration with Bosch Rexroth, whose Connected Hydraulics seamlessly integrates digitalisation, IoT connectivity, and automation into hydraulic systems. By transforming traditional fluid power into intelligent, highly efficient solutions, these innovations enable real-time data monitoring, predictive maintenance, and seamless system integration. As a result, manufacturers can significantly reduce downtime, optimise energy consumption, and enhance overall productivity. These smart systems adapt to operational demands, ensuring precise control, minimised waste, and a reduced total cost of ownership, ultimately shaping a forward-thinking, sustainable, and competitive industry model.
A sustainable future for Bosch Bamberg
With the successful implementation of the CytroBox, Bosch Bamberg is taking a decisive step towards the future of smart manufacturing. The plant’s commitment to reducing energy consumption and CO2 emissions, combined with Rexroth’s innovative hydraulic solutions, sets a new standard for intelligent, sustainable industrial production. This collaboration demonstrates that modernising hydraulic systems is not just about improving performance—it’s about creating a smarter, greener, and more connected manufacturing environment for the future.
