Background

Xella Porenbeton (formerly Hebel) is a leading manufacturer of aerated concrete blocks with annual sales of over €120 million. A new plant is to be built to expand the business regionally. PI was commissioned to design the new plant with state-of-the-art process technology and construct it on a greenfield site.

Results

• Factory commissioned, capacity expansion
• Significant increase in productivity

PI services

Factory planning, process planning, logistics planning

Concept design 
analogous to VDI 5200, phases 1 to 3

• Production segments and organisation defined
• Logistics concept (material flow, control principles, storage and conveyor systems) created
• Resources (personnel, equipment, buildings) dimensioned
• Rough concept for plant development created
  • Investments, costs
  • Greenfield layout
  • Master plan for implementation

Detailing
analogous to VDI 5200, phases 4 and 5

• Process technology (especially dosing, drying) defined
• Production segments and islands in detail
  • Machine layout plan created
  • Piping and instrumentation diagram (P&ID) for media supply and disposal created
  • Plant list created
  • Plant technology specified
• Storage and conveyor technology specified
• Plant, storage and conveyor technology tendered, quotations obtained and prepared for award
• Buildings and technical systems specified
• Engineering firms requested, selected and involved
  • Architect and structural engineer
  • Heating/ventilation/plumbing
  • Expert (soil surveyor, fire protection)
• Prepared approval documents (Federal Immission Control Act) and obtained approval
• Prepared budget and schedule, established project controlling

Implementation
analogous to VDI 5200, phases 6 and 7

• Details agreed with suppliers
• Interfaces with customers (planning, production, maintenance) and other suppliers or service providers (construction, media, etc.) coordinated, solutions developed
• Proper provision of individual services monitored and controlled
• Commissioning, rectification of defects, MFU/performance tests and acceptance coordinated
• Budget (investments) tracked
• Project progress recorded: minutes, photos, schedule
• Engineering offices managed (senior site management)

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

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

Trades

Weighing and dosing equipment, mixers, dryers, autoclaves, precision cutting systems, hydraulic cranes, storage and conveyor systems, production hall, laboratories, and offices