Process
Engineering

A floor plan does not come about by chance – it is the result of an overall concept precisely tailored to the process. Only when processes, hygiene requirements, technology, and logistics interlock can a layout be created that functions permanently. Whether equipment cleaning takes place in the correct hygiene zone, how media and technical centers need to be dimensioned, or how material and personnel flows are optimally managed – such central questions can only be answered interdisciplinarily.

A viable layout does not arise by chance – it is based on a thorough analysis of processes, risks, and interfaces. Key questions must be clarified at the very beginning of a project:

We accompany you from the initial vision to technical implementation. With our expertise, we create process flow diagrams (PFD/P&ID), define requirements in specifications, and develop initial 3D layouts as a basis for informed decisions.

In the GMP environment, a precisely formulated specification is the foundation for successful project implementation and subsequent qualification. We prepare reliable tender documents for you that clearly define all relevant requirements and unambiguously and contractually describe all interfaces – no more and no less.

If simultaneities, actual connection values, or real load profiles are not critically questioned, this quickly leads to oversized and uneconomical supply systems.
We analyze your needs precisely and reliably. If project-specific consumption data is available, we integrate it into our calculations.

Using proprietary or commercial software such as FluidFlow (R) or Inosim (R), we simulate distribution and storage systems. Whether it’s the tank level in the WFI system or the hydraulics after the outlet – we know where to look. Where it is worthwhile to perform complex calculations. And where it is not.

For production in three-shift operation, crucial questions arise: Will the weighing become a bottleneck? How many buffer tanks are actually required? What impact will delays in cleaning cycles have? And what is the real peak demand for steam or other media?

How is delivery organized? How many pallets leave production per hour? What size must the buffer area be to ensure stable operation? We analyze goods flows, calculate capacities, and develop reliable logistics concepts – from goods receipt to dispatch.

We plan your process and your facilities – and consistently accompany them until successful regular operation. Already during the tendering phase, we assist with initial supplier visits and technical clarifications. From Factory Acceptance Test (FAT) to Site Acceptance Test (SAT) and structured commissioning, we coordinate all steps and interfaces.

Quality deviations should not become apparent only during assembly or qualification – for example, if a nozzle has warped due to improper welding or unspecified material has been installed. To exclude such risks early on, we rely on structured Technical Quality Assurance. This includes, among other things, supplier audits, material mix-up tests (PMI), weld seam inspections, and accompanying control of manufacturing processes.

You know your process best. We both know why the layout was planned this way. What is the material flow? We have a zone jump here. But is that actually a problem? We are happy to accompany you in presenting your project to the authorities even at an early stage. And we stand firmly by your side during the inspection when it comes to granting the manufacturing authorization.