Pune, India | October 06, 2025
KAPP NILES has unveiled the KNG 5P expert, a highly efficient and versatile profile grinding machine designed to meet the diverse and demanding needs of modern gear manufacturing. This innovative system combines exceptional precision, flexibility, and user-friendly ergonomics within a compact design that can integrate seamlessly into space-constrained production environments. By focusing on both performance and adaptability, KAPP NILES has delivered a solution that supports a wide range of applications, making it an optimal choice for manufacturers across various industries.
As industries demand increasing accuracy and customization in gear production, KAPP NILES responded by developing the KNG 5P expert to provide a perfect balance between quality and operational flexibility. This machine accommodates internal and external gear grinding, pinion shafts, and worm profiles, allowing users to tackle complex jobs with high efficiency. Its versatility not only enhances productivity but also helps manufacturers optimize their shop floor by reducing the machine footprint.
A key feature of the KNG 5P expert lies in its directly driven grinding spindle, which offers up to 64 Nm of torque and achieves speeds of up to 9,500 RPM. The machine supports grinding wheels ranging from 60 to 350 mm in diameter, further enhancing its application breadth. Additionally, it can handle face widths up to 670 mm, enabling the grinding of large-diameter components with unparalleled precision and consistency.
The tailstock design adds to the machine’s flexibility by being infinitely adjustable and fully swivable out of the working area. This improves operators’ efficiency in setup and part handling. The grinding process benefits from a robust tip pressure up to 2,000 N, ensuring reliable clamping during demanding operations and minimizing the risk of part movement or vibration.
Transitioning from setup to active grinding is streamlined thanks to the machine’s ergonomic design. For example, the dressing spindle can be externally rotated to a parking position. This feature allows operators to change diamond dressing tools quickly without entering the grinding chamber, reducing downtime while enhancing safety and accessibility.
The rotary table is another standout element, featuring a 400 mm diameter and a central bore. This setup enables the processing of longer shafts and a wider range of components, making it suitable for manufacturers who require flexibility in the types of parts they produce. Despite these advanced capabilities, the machine maintains a compact footprint, making it ideal for shops with limited floor space.
Moreover, the KNG 5P expert addresses one of the toughest grinding challenges—worm grinding with pitch angles up to 45°. KAPP NILES integrated a dressing arm that fully retracts from the grinding area during operation. Consequently, the machine can utilize the entire 675 mm stroke, providing greater freedom in manufacturing complex worm gears and expanding the range of possible applications.
On the technological front, KAPP NILES equips the KNG 5P expert with intuitive CNC controls that offer five-axis interpolation. This capability allows precision movements and complex grinding tasks, while automated features such as CNC-controlled cooling nozzles and robotic loading interfaces streamline integration into automated production lines. These enhancements make the machine suitable not only for job shops requiring precision but also for manufacturers demanding high-volume production.
Boris Maschirow, product specialist at KAPP NILES, explained that the KNG 5P expert serves as a next-generation successor to their widely respected ZE series. “We listened carefully to our customers’ feedback,” he noted, “and built on the strengths of ZE machines by adding modern technology and improvements. This new system delivers enhanced flexibility, superior gear quality, and noticeably shorter changeover times.”
Many innovations featured in the KNG 5P expert came directly from customer input. Among these are improved machine accessibility, enhanced grinding speeds, modular expansion options, and energy-efficient operation. KAPP NILES ensures every component aligns with current industry trends in mobility, automation, and energy conservation, reflecting their commitment to sustainable and advanced manufacturing solutions.
The KNG 5P expert is not a generic offering; rather, it allows extensive customization through configurable modules. Customers can add advanced tool changers, automated dressing systems, or fully integrate the machine into digital manufacturing cells. This modularity provides a strategic advantage for a variety of production approaches, ranging from small batch sizes to larger series production runs.
KAPP NILES, headquartered in Germany with a global footprint, boasts decades of experience in machining technology. The company emphasizes precision, durability, and designs centered around customer needs. Its comprehensive approach encompasses machinery, tooling solutions, metrology equipment, and service support. This integrated support allows users to consistently achieve micron-level tolerances essential for high-quality gear manufacturing.
In conclusion, the KNG 5P expert represents a significant advancement in profile grinding technology. Its combination of high torque, flexible configuration, intelligent design, and user-focused features equips manufacturers with a powerful tool for demanding gear applications. For businesses seeking to enhance performance, precision, and productivity, the KNG 5P expert offers a forward-looking solution from KAPP NILES that addresses current and future manufacturing challenges.
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