How did di-soric come to focus on customized sensor solutions?
Customers in machine and plant engineering are pursuing increasingly ambitious goals in terms of productivity, flexibility, and reliability. Standard components often reach their limits when faced with these demanding requirements.
To achieve the final 5 to 10 percent of efficiency gains, we work closely with our customers to develop customized solutions based on robust standard products.
In doing so, we not only ensure maximum process reliability while offering a high degree of customization, but also create significant competitive advantages by addressing our customers’ specific challenges in a targeted manner.
How extensive is the customization of your sensor solutions?
Our customization capabilities cover mechanical, electronic, and software modifications, which can be highly extensive. Thanks to our high level of vertical integration, we can implement virtually any modification within our existing product families without compromising the proven reliability of our products.
We rely on modular designs and comprehensive customer-specific software development. In addition, we utilize flexible manufacturing processes such as additive manufacturing. This enables rapid prototyping, short-notice design changes, and the cost-effective production of complex and unconventional geometries that would be difficult or impossible to achieve using traditional manufacturing methods.
All of these capabilities allow us to implement even highly complex customer requirements quickly and economically.
Can you provide specific examples of benefits customers have achieved through customized sensor technology?
A typical example is end-of-line inspection in assembly automation. Customized sensors can significantly reduce the number of inspection stations required, resulting in substantial savings in floor space, capital investment, and cycle times.
In the packaging industry, we have increased productivity through specially developed fork sensors by maximizing the number of products inspected simultaneously during each cycle.
Additional measurable benefits include reduced downtime, improved maintenance intervals, and higher overall equipment availability.
Beyond the expected reliability and quality, customized sensors also improve ease of operation and help prevent errors. Through targeted adaptations of sensor software, we minimize the risk of operator mistakes, ultimately enhancing process stability.
Factors such as maintainability, accessibility, and seamless integration into existing machine structures are also considered from the outset when developing custom solutions.
»Companies often invest significant effort in adapting their equipment to existing standard sensors and, in doing so, lose considerable optimization potential.«
Does customization also mean deliberately simplifying sensors?
Absolutely. By deliberately simplifying sensors, we focus them precisely on the core requirements of a specific application. This not only improves robustness but also significantly extends service life, even under the most demanding operating conditions.
Particularly in challenging environments with high levels of contamination or significant mechanical stress, such targeted simplifications can substantially improve sensor durability and longevity.
What role does IO-Link play in customized sensors?
IO-Link plays a central role because it significantly increases the flexibility of our sensor solutions. It enables data-driven optimization, supports predictive maintenance strategies, and offers major advantages during product and format changeovers.
Parameters can be configured centrally and consistently through the control system, enabling fast, precise, and repeatable machine commissioning anywhere in the world.
This not only reduces complexity but also improves overall equipment availability and operational efficiency.
To what extent do you modify software?
The proven core functionality of our sensors always remains unchanged to ensure maximum reliability.
Software modifications therefore typically focus on the user interface, specific parameter settings, and application-specific algorithms. We implement extensive adaptations of interfaces and data-processing methods to precisely meet individual customer requirements and achieve optimal performance.
»Just ask—there are often customized solutions available that many companies never thought possible.«
How does customization affect the cost of sensor solutions?
Customized solutions are not automatically more expensive than standard products.
Although initial development and tooling costs are incurred, these investments typically pay for themselves within two to three years. For products with longer life cycles—often five years or more—customized solutions can be exceptionally cost-effective.
The key is transparent communication and accurate calculation of both one-time and recurring costs, providing customers with full cost transparency and planning reliability.
What production volumes make customized solutions worthwhile?
Customized sensor solutions become economically attractive at annual volumes of approximately 500 to 1,000 units.
Given the long life cycles of our products—often well beyond ten years—a custom solution can quickly deliver sustainable economic benefits.
In practice, there are many examples of our customized sensors remaining in service, unchanged and highly reliable, for more than 15 years. This demonstrates not only their technical reliability but also their long-term economic value.
In summary, why should companies choose di-soric for customized sensor solutions?
Companies seeking fast, transparent, and reliable assessments of technical feasibility, combined with precise cost calculations, will find the ideal partner in di-soric.
Our extensive expertise, high level of vertical integration, transparent project management, and collaborative approach minimize project risks while maximizing long-term success.
Companies should not hesitate to inquire about customized solutions, as they often deliver substantial savings when viewed in the context of the overall automation system.
Is there anything else you would like to share with our readers?
We would strongly encourage customers to contact us and actively inquire about customized solutions.
Many companies invest considerable effort in adapting their equipment to existing standard sensors and, as a result, miss significant opportunities for efficiency improvements. In many cases, relatively small modifications to the sensor itself could greatly simplify the overall machine design and generate substantial savings.
That is why an early dialogue with us is worthwhile. Together, we can identify a tailored solution that is both more cost-effective and technically better suited to the specific application requirements.
Users can find more information and examples of customized sensor solutions at
https://www.di-soric.com/int-en/competence/areas/individual-standards
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