Success story

Insulation Kits for Uninterruptible Power Supply

September 29, 2026

Global energy demand is rising, and with it the requirements for a reliable, uninterruptible power supply. The expansion of data centres in particular, driven by the boom in AI applications, increases demand for systems that safeguard critical infrastructure.

One of our new customers develops and produces such systems for data centres, hospitals and other critical infrastructure. Large electrical machines work together with mechanical energy storage that is kept permanently in motion and delivers energy immediately when required.

Demand for these systems is high. To expand production capacity significantly over the coming years, it was not only the main products that had to be manufactured more efficiently, but also the upstream steps that until then were carried out by hand.

Starting point: insulation parts made in-house by hand

Until then the customer produced the insulation parts for the large electrical machines largely in-house. NPN and NKN insulation materials were purchased as slit rolls and as wide stock in various widths. Slot liners, separators and slot closures were cut to size by hand on a guillotine shear and partly formed manually on a folding machine.

A process that had worked for years, but became increasingly time and labour intensive as volumes grew. Cutting from wide stock created offcuts, and the quality of the forming depended more on the individual working step than on the machine.

The solution: automated production at Hauler & Hermann

Together with the customer we moved the previously in-house parts into an automated process at Hauler & Hermann. We produce the various slot liners, separators and slot closures from NPN and NKN insulation materials, matched to each machine.

The result is precise, reproducible parts with a defined shape. Pre-forming is the decisive step: the customer used to do it in-house, today the parts arrive ready to install. They are taken out and fitted, with no rework.

Less waste, less manual work, higher process reliability

Instead of buying wide rolls and cutting every part in-house, the customer receives the required geometries directly. Material is used more efficiently and offcuts drop by around 20 percent.

At the same time, time-consuming manual steps such as cutting and forming are eliminated. Automated production on our punching and folding lines delivers consistent dimensions, independent of operator and quantity. A labour-intensive internal step becomes a scalable procurement process.

Packed ready for assembly as a kit per machine

On request we deliver the parts not as loose line items but assembled into a kit per machine, packed ready for assembly. One kit holds the insulation parts for exactly one machine: slot liner, slot closure and phase separator.

Assembly picks up one kit instead of several stock positions, and the number of purchase orders drops. Whether kit or individual items is the customer's choice.

From production

Converted insulation parts in stock, packed and marked per item

Assembly-ready kit: the pre-formed insulation parts for one machine, labelled and packed together

Slit rolls of NPN and NKN as the base material for the insulation parts

Frequently asked questions

Which insulation parts are used in a UPS system?

The large electrical machines in UPS systems contain slot liners, separators and slot closures, typically made from NPN and NKN insulation materials. The selection depends on thermal class, slot geometry and impregnation process.

Why outsource insulation parts to a specialist?

Because cutting and forming by hand scales with quantity while automated production does not. Alongside lower labour input, offcuts are reduced because parts are no longer cut from wide stock, and dimensional accuracy becomes reproducible.

What is an assembly-ready kit?

All insulation parts for one machine, that is slot liner, slot closure and phase separator, are assembled into a set and packed together. Assembly takes one kit instead of collecting individual items from different stock locations.

From which quantity does the changeover make sense?

That depends on the range of parts and the geometry. We produce from samples to high-volume series and work the changeover through with you. Send us your drawings via the contact form.