Background

Keimfarben GmbH in Diedorf ("Keimfarben") manufactures and distributes high-quality mineral paints and tinting bases for exterior facades and interiors. Customers are increasingly buying paints that are manufactured individually and at short notice. This requires a new production concept. Keimfarben wants to expand its plant to accommodate planned growth and more customized production. Keimfarben commissioned Projektingenieure (PI) to design this expansion.

Results

• Multi-stage plan for expanding the plant
• P&ID diagram and plant concept in 3D for the new production facilities
• Integrated hall (plan) for
  • Raw material storage (silos, tanks, big bags)
  • Production (dosing, mixing, filling, packaging)
  • Logistics (transport, storage, shipping)
• Process optimisation and productivity enhancement
• Implementation of the highest standards of occupational safety, environmental protection and energy efficiency

PI services

Factory planning, process planning, logistics planning

Concept design
analogous to VDI 5200, phases 1 to 3

• Target process defined
  • Storing raw materials (silos, tanks, big bags)
  • Weighing, dosing
  • Mixing (paddle mixer)
  • Filling
  • Packaging
  • Transporting (within the company), storing
  • Shipping
• Piping and instrumentation flow diagram (P&ID) created
• Plant dimensions determined
• Plant expansion options created and evaluated
• Plant concept and buildings created in 3D
• Personnel and media requirements determined
• Investments calculated
• Master plan for implementation created

Topics

Factory planning: Value stream, production segments, material flow, layout, scalability, step-by-step expansion, facilities/infrastructure/buildings, cleanliness, environmental protection

Process planning: Process engineering, plant engineering, simulation of capacity requirements, automation, interlinking, energy efficiency, IT, control technology, machine and process data acquisition, Industry 4.0

Logistics planning: Simulation of movements/inventories, conveyor technology: Warehouse technology/transport technology

Trades

Storage technology (silos, tanks, big bags, high-bay warehouses), dosing technology, weighing technology, mixers (paddle mixers), filling systems, packaging systems, conveyor technology (AGVs, shuttles), automation, control technology