Sondermaschinenbau: a guide to special purpose machinery manufacturing, from design to commissioning
What is Sondermaschinenbau?
Sondermaschinenbau —special purpose machinery manufacturing— encompasses the development, engineering and manufacture of machines and systems designed specifically for a particular production process. Unlike series production, where standardised machines are produced in high volumes, each special purpose machine is created as a one-off or small batch, tailored to the customer's requirements.
Sondermaschinenbau demands the integration of multiple engineering disciplines under one roof: mechanical design, CNC machining, electromechanical assembly, SPS/PLC programming, robotics and commissioning. It is precisely this vertical integration that sets a capable special purpose machinery manufacturer apart from a mere design office or a contract machining shop.
At MECVIL in Sallent (Barcelona), we have been manufacturing special purpose machinery for over 50 years across 13 industrial sectors. With +110 professionals, 10,500 m² of production floor space and ISO 9001 and EN 1090 certifications, we are positioned as a European technology partner for OEMs and engineering firms in the DACH region.
The 6 phases of a Sondermaschinenbau project
A turnkey special purpose machinery project passes through six sequential phases:
- 1.Concept and feasibility study: analysis of customer requirements, functional definition, initial cost estimate and scheduling
- 2.[Detail engineering](/en/servicios/ingenieria): 3D CAD design, FEA simulation, electrical schematics in EPLAN and See Electrical, bills of materials and manufacturing drawings
- 3.Mechanical manufacturing: CNC machining of machine beds, jigs and structural components. At MECVIL, with CNC milling machines with up to 20 metres of travel and simultaneous 5-axis machining
- 4.[Electromechanical assembly](/en/servicios/montaje): mechanical, electrical, pneumatic and hydraulic assembly. Switchgear cabinet manufacture, wiring and installation of all components
- 5.[SPS/PLC programming and commissioning](/en/servicios/electrica): programming of Siemens, Omron, Panasonic and Mitsubishi PLCs, HMI configuration, robot programming, machine vision systems, FAT (Factory Acceptance Test)
- 6.Delivery and SAT: transport, installation at the customer's site, commissioning under production conditions (Site Acceptance Test), operator training
At MECVIL we carry out all six phases in-house — as part of our 360° turnkey service. No subcontractors for PLC programming, no external switchgear builders, no third-party commissioning engineers. A single point of contact for the entire project.
Looking for a special purpose machinery manufacturer with integrated production?
Contact our engineering team and we will analyse your project requirements.
Why special purpose machinery rather than standard machines?
The decision to opt for a special purpose machine is the right one when:
- The production process cannot be addressed with standard machines
- Multiple operations (assembly, inspection, marking, packaging) need to be combined in a single integrated system
- Specific cycle times or quality requirements demand a bespoke solution
- The degree of automation exceeds what configurable standard machines can offer
- Sector-specific regulations (food, pharmaceutical, automotive) call for special materials, finishes or documentation
A concrete example: for the automotive industry we have built FMS lines with up to 5 robots that assemble electronic components, inspect them with machine vision and fasten them automatically — all in a continuous line with full traceability.
What technologies does MECVIL employ?
Machining and large-part manufacturing
Our CNC machining capabilities include:
- Milling machines with up to 20 m of travel — the first of their kind in Catalonia (since 1996)
- [Simultaneous 5-axis machining](/en/servicios/mecanizado/mecanizado-5-ejes) for complex geometries
- CNC turning for large-diameter rotational parts
- Precision grinding for tight tolerances down to ±0.005 mm
- 3D coordinate measurement for comprehensive quality documentation
Control systems and robotics
Our electrical engineering team programmes:
- SPS/PLC: Siemens (S7-1200, S7-1500), Omron, Panasonic, Mitsubishi
- HMI: Siemens, Omron, Proface
- [Industrial robots](/en/noticias/robotica-industrial-aplicaciones): integration into assembly cells and welding stations
- Machine vision: AOI systems, 2D cameras, 3D profilometers, QR/barcode readers
- Servo motors with regenerative braking energy recovery
Welding
In our 600 m² welding shop we manufacture welded assemblies and structural components under EN 1090 certification. This includes robotic welding cells with positioners and dual stations.
Why commission a Spanish special purpose machinery manufacturer?
For DACH companies, partnering with a Spanish special purpose machinery manufacturer like MECVIL offers tangible advantages:
- Cost efficiency: manufacturing costs in Spain are approximately 30–40% below the German level, with equivalent qualifications and certifications
- EN 1090 and ISO 9001: our certifications are recognised across the EU — your steel structures require no additional approval in Germany
- 50 years of experience: we have been building special purpose machinery since 1976 — longer than many German companies in the sector
- European technology partner since 2018: we already work with OEMs and engineering firms across Europe
- Same PLC brands: we programme Siemens, Omron and Mitsubishi — the same brands specified in DACH specifications
- Logistics: Barcelona is a 2-hour flight from Munich or Zurich. Project visits can be arranged with minimal travel effort
Looking to realise a Sondermaschinenbau project with an experienced European partner?
MECVIL offers engineering, CNC machining up to 20 m, electromechanical assembly and SPS/PLC programming under one roof. Get in touch for a no-obligation project consultation.
Sectors and reference projects
Our Sondermaschinenbau serves [13 industrial sectors](/en/empresa), including:
- Automotive: FMS assembly lines with 5 robots, machine vision, automatic fastening. 12-station lines with inline final inspection
- Chemical: fully automated robotic tablet presses for chlorine tablets
- Heavy machinery: roller construction, calenders, cutting and polishing machines for vessels up to Ø3,500 mm
- Hydraulics: pipe winding machines with integrated pressure testing
- Packaging: unwinders and rewinders for industrial packaging lines
These projects demonstrate that Sondermaschinenbau at MECVIL goes beyond engineering — it encompasses complete manufacturing, assembly, programming and commissioning — all from a single source.
Quality assurance in special purpose machinery manufacturing
Quality in special purpose machinery manufacturing means more than an ISO certificate:
- ISO 9001: quality management system with traceability and continuous improvement
- EN 1090: certified execution of load-bearing steel and aluminium structures — essential for structural components in special purpose machinery
- [CE conformity](/en/noticias/directiva-maquinas-marcado-ce): as the manufacturer of the complete machine, we assume CE responsibility in accordance with the new EU Machinery Regulation 2023/1230
- Dimensional control: 3D coordinate measurement with documented inspection reports for every critical tolerance
- FAT/SAT: factory acceptance testing at our facilities and site acceptance testing at the customer's premises, with documented protocols
We apply Lean Manufacturing principles throughout our production process to minimise lead times and maximise efficiency — even in one-off production.
The next step
Special purpose machinery manufacturing is not a service you order from a catalogue. It is a partnership between the customer, who understands the process, and the manufacturer, who brings production expertise. The right choice of partner determines the quality, timelines and cost of the project.
Planning a Sondermaschinenbau project?
At MECVIL we bring together engineering, CNC machining, welding, assembly, SPS/PLC programming and commissioning across 10,500 m² of in-house production. Contact us about your project.