Process Consulting

From an idea to the optimal investment: Process Consulting with Hosokawa Alpine AG

Industrial facilities are large investments that need to be carefully prepared. Hosokawa Alpine's Process Consulting supports customers in the holistic planning of their production processes. The focus is on three steps, the result of which is a sound decision-making basis for a successful investment.

Holistic view of the process

When the construction of a new system or individual process steps is on the horizon there is a lot to consider. Hosokawa Alpine, one of the leading suppliers in the field of mechanical process engineering and film extrusion, provides versatile support in the industrial implementation of mechanical process engineering projects with its Process Consulting business unit. With the concentrated expertise of the Hosokawa Group as the backdrop, the team led by Process Consultant Christian Eisenbarth simulates processes precisely, takes all steps into account and, in doing so, views the process holistically. This means that customers are accompanied through all the planning phases.

Defining the task and requirements

The first step is to nail down the ideas and define the specific task. Taking a close look at the bulk or grinding material, the requirements for the future system are outlined and all individual specifics such as quantities, sustainability, installation space or integration into already existing systems are taken into account. A feasibility study provides information on the current and target status. This includes component or system tests, comparisons of different technologies and the advised time to market. All the information flows into an initial specification document that records the product, process and general conditions (e.g. ATEX, IECEx or other requirements). Finally, customers receive a rough implementation concept with a process flow diagram and an initial cost estimate.

Investigating alternative scenarios

In the second step, several solution paths are elicited for the customer's individual requirements. This includes tests to check technical feasibility, initial process flow diagrams and a cost analysis in terms of OPEX and CAPEX. At the end, there are various process proposals and an evaluation of these alternatives. Automation pre-planning and the specification of components are also reviewed. "The success of a plant starts with the right planning. Especially for high-cost investment projects, early validation is important to reduce project risks and keep an eye on the costs. This is what we can achieve with our offer and, in doing so, help to accelerate the project processes," explains Christian Eisenbarth, Process Consultant in the Technical Division at Hosokawa Alpine.

Visualising solutions

In the final step of Process Consulting, the Hosokawa Alpine experts examine the various options in more detail in order to create an optimum foundation for the customer's decision. This includes risk analyses and decision matrixes, flow diagrams and a 3D visualisation with the customer's individual main process components and building structures. "Our goal is that in the end we were able to work with our clients to develop a process that best meets their needs, giving them a sound basis for the rest of their business plan. It is definitely worth making use of a consultation: Thanks to our many years of experience with individual processes, we achieve optimal results together with our customers", explains Christian Eisenbarth.

The perfect powder process

To find the right powder process, Hosokawa Alpine's Process Consulting team takes many different components into account.