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Base estimates, initial planning, and design

Site analysis

In order to be able to make investment decisions, it is necessary to carry out a site analysis and possibly also a site comparison, including a corresponding assessment, at the time of the base estimate.

In the process, site criteria are aligned with various aspects. On one hand, economic aspects have to be considered, such as investment costs, proximity to the customer, and sales opportunities. On the other hand, aspects of environmental legislation and process engineering come into play. Primary importance is assigned to the location of the future installation from a construction perspective, the proximity to property requiring protection, nature conservation and immission control, or logistics. Issues having to do with the essential design of the factory should also be considered in this work step and contribute to the decision making process.

We determine the site and assessment criteria for the site analysis in consultation with you. We then independently source detailed information, assess the findings from an engineering perspective, and evaluate the results. At this point, a cost-utility analysis can also provide useful insights. Next, we compile the necessary data for you, produce drawings, and analyze exclusion criteria. Finally, we submit a recommendation for your decision.

Process engineering design

To draft the process engineering design, we independently source detailed information, assess the findings from an engineering perspective, and evaluate the results. At this point, a cost-utility analysis can also provide useful insights. Next, we compile the necessary data for you, produce drawings, and analyze exclusion criteria. Finally, we submit a recommendation for your decision.

  • Clear representation of the process in a block flow diagram with volume flows
  • Selection of major process engineering components and representation in a process flow diagram in accordance with DIN EN ISO 10628
  • Drafting of a preliminary equipment layout plan as a basis for the design of the structural systems
  • Presentation of design variants in preparation for the customer decision

Factory design and logistics planning

As part of our factory design and logistics planning service, we provide support in producing a design for your prospective plant that meets the criteria for approval and that is, above all, practical. It makes no difference whether the objective is a new building or the modification, redevelopment, or expansion of existing facilities. 

As part of a holistic planning process, we differentiate between the following areas: 

  • Site planning: Identification of a suitable site, factoring in site criteria
  • Layout planning: Drafting of workable layouts including selection and arrangement of buildings, traffic routes, and layout of industrial manufacturing equipment
  • Factory work breakdown structure: The size and structure of production and logistics systems including the required plans in terms of personnel and organizational arrangement

We use a range of planning tools. Collaboration between our engineers and specialists ensures a holistic design concept by drawing together different fields of knowledge. Starting from your vision, and incorporating process engineering sequences and local and structural conditions, we create digital layouts, equipment and machinery layout plans, and process flow diagrams in accordance with DIN EN ISO 10628. These are used for further stages of design and implementation. The facility is then optimized by integrating additional criteria. In this phase, the primary concern is improving logistics (e.g. material flow). We are also happy to prepare and assess variants for you.

Construction design

Construction design is a subprocess of construction planning whereby the client's vision is illustrated through the execution of the plans for the construction project. It is also often referred to as a planning phase known as "design documentation" in the German Fee Regulations for Architects and Engineers (HOAI). This is the phase in the planning process where the design is drawn up.

Construction design and design documentation are carried out by architects and engineers. The aim is to achieve a harmonious and realizable design concept that factors in all project-specific considerations. Responsible construction design must take into account current regulations as well as currently available technological developments. The construction design is also influenced by functional, constructive, and artistic planning decisions.

Environmental engineering: comparison of options for air pollution control and exhaust gas cleaning

Air pollution control plays an important role in all industrial sectors – choosing an appropriate and efficient exhaust air or exhaust gas cleaning system is absolutely essential.

Based on information provided by you (description of the facility and processes, substances in the exhaust air, emissions) and the requirements of the TA Luft instructions on air quality control, we produce a design for a suitable exhaust air or exhaust gas cleaning system. When making our selection, we consider all the principal processes of physical, biological, and chemical cleaning and combinations thereof. The technical, economic, and ecological assessment of potential systems is at the heart of the design process, together with a consideration of advantages and disadvantages. We would also be more than happy to draw up tender specification documents for you as well as receive and evaluate bids.

We are in close contact with producers and suppliers of exhaust gas cleaning equipment and keep ourselves up to date on the latest developments. These innovations are, of course, included in our design concepts.

Energy design concepts

We determine the actual state of your company's power systems on site and assess these with respect to legal compliance and the latest technology. On the basis of this assessment, we submit recommendations for potentially improving your exploitation of energy sources. We also provide you with designs for the implementation of these proposed solutions, cost benefit analyses, and estimates.

Risk assessment in the planning phase

in line with the Machinery Directive (FMEA, HAZOP, DIN EN ISO 14121-1:2007)

The new Machinery Directive 2006/42/EC has been in place since 2010. The Directive further defines the requirements for a risk and/or hazard assessment and emphasizes the need to carry this out on the product during the planning phase. Accordingly, the manufacturer of a machine or plant has to identify which fundamental health and safety requirements are applicable and which measures are required right from the concept and design phase. There are a range of methods available for doing this, including FMEA, HAZOP and HACCP.

After completing or installing a plant or piece of machinery, we assess potential hazards on the basis of prescribed evaluation criteria, applicable legislation, provisions of the employer's liability insurance association or professional association, and DIN standards. We carry out a targeted inspection on site on the basis of DIN EN ISO 14121 and DIN EN ISO 12100, systematically identifying, describing, and recording hazards. We then assess these hazards, demonstrate the existing hazard potential, and establish the necessity of taking remedial action. As an output of the risk assessment, you will receive documentation including suggested improvements for eliminating machine- or plant-related hazards or reducing these to an acceptable level. With us, you'll be on the safe side from the moment you start up your new machinery or plant.

Estimate of costs in line with DIN 276

We carry out costing in line with DIN 276. This can provide the basis for financing, cost specifications, cost control, and cost management measures, or planning, tendering, and design decisions. As an alternative, an estimate of costs can also be used to substantiate accrued costs.

In construction, in line with DIN 276, costs are subdivided into the stages of budgeting, estimation of costs, calculation of costs, and establishment of total cost. These are specified according to their purpose, the necessary bases, and the degree of detail. The degree of detail increases from the budgeting stage through to the establishment of total cost.