Turnkey extraction system including engineering and CE certification for modern production processes

To optimize production processes, SPIE AUTOMATION delivered a turnkey project for the planning, delivery, and installation of a complete extraction and filtration system, including CE certification. The system reliably extracts production waste, filters the process air, and returns it cooled to the production hall. All services—from concept development to commissioning—came from a single source.

The piping design is shown on a PC.
Fig.: Turnkey project © SPIE AUTOMATION

Challenge and Objective

The customer needed a high-performance extraction system that reliably extracts and filters production waste and returns the cleaned air without additionally heating the hall. At the same time, the entire project—from the feasibility study and technical planning through to CE certification—was to be delivered by a single partner.

To achieve this, various technical and economic options were first evaluated, and the system was calculated and designed from a process engineering perspective. This was complemented by a feasibility review, structural calculations, and detailed planning of the system components and piping.

Solution

The departments involved in delivering the project were Process Engineering (VT), Assembly and Relocation Central (MVM), Assembly and Relocation South (MVS), and Automation 1 (ATM1). Thanks to close collaboration between the specialist teams, the project was implemented in full as a turnkey solution without external interfaces.

At the outset, the system concept was developed together with the customer and technical feasibility was assessed. Based on this, the process design of the system was carried out, including sizing the filter, fan, cooler, and after-filter. In parallel, structural calculations were performed and the fastening and structural requirements were coordinated together with partner Hilti.

For detailed planning, the existing production environment was digitally captured using a 3D laser scan. Using the modeled 3D model, piping, steel structures, and HVAC ducts were jointly planned in AutoCAD and coordinated to be collision-free. In addition, sound insulation was designed based on an acoustic report.

In parallel, the ATM department developed the complete automation solution. This included planning the control software, designing the control cabinet, and specifying the electrical connection and all cable routes, as well as the installation.

After the engineering phase was completed, all components were procured and installed. Throughout the entire project, weekly project meetings were held to align schedules, technical changes, and decisions. Despite challenges such as structural requirements, building permits, ongoing production, and weather-related restrictions for outdoor installations, the project was successfully delivered. The final steps were commissioning, the risk assessment, and full CE certification of the overall system.

Benefits

With the new system, the customer now has a modern, high-performance extraction and filtration solution with high efficiency, reduced noise levels, and cooled return air. Because all services were delivered from a single source, time-consuming coordination between different suppliers was eliminated. In addition, with current utilization of around 35%, the system offers sufficient capacity reserves for future expansions and can also be maintained by SPIE AUTOMATION in the long term.

These SPIE AUTOMATION strengths were applied

About our customer

Our customer is an internationally operating industrial company with sites worldwide. The company develops, manufactures, and assembles its products under its own responsibility, relying on high quality standards and modern manufacturing processes.

Industry
Industrial

Fig.: Real view versus planning view

Overall, the project was very demanding and challenging at times. Nevertheless, I am very satisfied with the implementation. After a two-year duration, numerous coordination rounds, and many changes, it was especially gratifying to see that all the effort paid off and the system works exactly as planned. What stands out in particular is that the project was delivered entirely from a single source—from concept and design through to commissioning as well as CE testing and certification. This turned an initial customer issue into a completely new, custom-built system that meets the requirements precisely.

Björn Blochwitz
Head of Assembly and Relocation Central / Authorized Signatory
SPIE AUTOMATION

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