Standard machines available off the shelf are not always sufficient to meet all industrial requirements. Where standard solutions reach their limits, custom-designed specialised machinery is required. This is precisely where VIRO comes in: at its ‘Plant 2’ in Hilter a.T.W., VIRO builds specialised machinery to meet its customers’ specific requirements, from the initial concept right through to turnkey handover.
Solving an industrial challenge that cannot be addressed, or can only be addressed to a limited extent, with existing machinery often presents a particular challenge. Design, mechanical manufacturing, electrical engineering, control and automation technology, as well as documentation, all need to be coordinated – often across different design offices, suppliers and system integrators. The responsibility for managing all these disciplines and interfaces lies with the customer. This not only ties up resources but also entails significant interface risks.
This is precisely where VIRO’s one-stop-shop concept comes into play. “Many customers have approached us with the request to have the machines we have developed manufactured directly by us,” explains Christian Prinz, Group Leader for Mechanical Engineering at VIRO. In response to this demand, VIRO decided to build ‘Plant 2’, an assembly hall covering around 600 square metres, in Hilter a.T.W. Naturally, the scope of services also includes technical documentation, machine safety, material compliance and the necessary calculations, as well as liaising with the relevant authorities where required. In this way, VIRO fulfils all the requirements and manufacturer obligations necessary for a machine to be ready for the market and placed on the market.
During implementation, VIRO relies on a carefully selected group of qualified suppliers for individual components and assemblies. VIRO brings together the mechanical assembly, electrical engineering and software in-house. Full responsibility for integration, comprehensive system testing and all adjustments and rework remains with VIRO throughout the process, right up to the machine being made available on the market in operational condition.
For clients, this means maximum peace of mind. “Throughout the entire project cycle, our clients have a single point of contact, from the initial meeting right through to the installation of the machine at their own premises,” explains André Weßeler, Head of Project Management at VIRO. “The client does not have to manage the various interfaces themselves and can track the machine’s progress as it is being built.” In addition to building new specialised machines, ‘Plant 2’ can also cost-effectively upgrade existing systems to the latest standards using modern control technology and safety adaptations.
Every order is based on a clearly defined and tried-and-tested project workflow that can be applied to almost any requirement. Ideally, the customer approaches VIRO with a requirements specification setting out their requirements for the machine. If no requirements specification is yet available, VIRO draws one up together with the customer, whether for the automation of existing processes or for a machine designed to perform a specific individual task.
VIRO responds to the requirements specification with a functional specification. Whilst the requirements specification describes what the machine is intended to achieve, the functional specification defines how these requirements are to be implemented technically. As part of this process, the engineers assess whether and how the requirements can be realised.
Based on the specifications, a detailed machine concept is drawn up, which forms the basis for further development. This encompasses the mechanical design, the electrical and control systems, as well as all safety-related documentation such as risk assessments and the CE Declaration of Conformity.
Many customers take advantage of the proximity to ‘Plant 2’ to oversee the construction of their machine on site. If required, VIRO also handles direct communication with testing bodies such as TÜV. At the end of the process, the machine is handed over to the customer on a turnkey basis.
The possibilities are primarily determined by the capacity of ‘Plant 2’. Regardless of this, any customer can submit an enquiry to VIRO for a custom-built machine. “We always deal with our customers openly and honestly during the consultation phase,” emphasises Prinz. “When jointly drawing up the specifications, we help the customer to further refine their requirements and provide a well-founded assessment of the extent to which these can be implemented.”
From the initial idea to the finished system, “Werk 2” in Hilter a.T.W. offers a comprehensive special-purpose machinery manufacturing service. Companies benefit from minimised risks, maximum transparency and a system that is precisely tailored to their requirements.
Dr. Florian Winter
Sales Manager
+49 175 985 0059
[email protected]