AZO®e&s

Pre-Engineering, Proofs of Concept & Feasibility Studies all from a single source

Our mission

As one of the most experienced manufacturers of plants and systems for automated materials and processes handling, we know exactly what the number one priorities are when developing production facilities that are viable for the future.

Our engineering team, composed of AZO experts, will support you with services relating to a multitude of questions on plant engineering and construction and making sustainable and effective use of your production plants.

We deliver solutions

We provide proofs of concept, conduct feasibility studies and analyse your processes. At the same time, comprehensive project management services are also available to you, as are individual planning and development packages. Likewise, we can research suitable process technologies on your behalf.

Our comprehensive understanding of production processes in the sectors of foods, pharmaceuticals, chemicals, cosmetics and plastics guarantees our ability to develop tailored solutions for you. A main focus of our work is retrofits:
plant refurbishment, expansion of existing plants, bringing control engineering up-to-date and in compliance with requirements.

We can assist you by using our individual 3D laser scans on your site for reliable planning of plants. We can conduct a survey of the current situation for you, support you in establishing the basis for the controls system and in updating plant documentation.The focus is always firmly maintained on keeping plant downtimes to a minimum and sequential commissioning in plants that are in production.

Range of services provided by the AZO®e&s department:

Raw materials analysis:

Safety data sheets
Technical specifications
Explosion characteristics
Raw materials analysis
Preparation and documentation for product data

Analysis of formulations/recipes:

Varieties of formulations/recipes
Structure
Components
Cross-contamination formulations
Required dosing rates
Annual capacities

Process analysis:

Types and sizes of containers
Timings for adding components
Media
Material flows / Staff
Cleanin

Review of the current situation:

Equipment
Buildings
Control engineering
Process / safety

Block diagram:

Preliminary / detailed planning
Prioritisation of information flows
Storage & production areas, zones, travel and transport paths, logistics
Manpower planning
Interfaces

Process flow diagram:

Process flow
Components & structure
Schematic diagram
More detailed representation

2D layout:

Components
Integration of existing buildings
Routes for staff
Product flows
Storage capacities
Maintenance rooms
Required production areas

3D layout:

Production facilities
Representations for specific sectors
Detailed height requirements
Location of equipment
Analysis of specific problem areas
Plans for penetration and loading plans

Piping & instrumentation Diagram:

More detailed process flow
EI&C symbols
Defined sizes & components
Dependencies as regards mechatronics

Considerations regarding media:

Media property check
Media survey

Interface consideration:

Existing equipment
Coordination for new plants

Demand & space planning:

Guarantee of supply
Communications with suppliers
Maintenance consideration
Spare parts

Consumer list:

Connected loads
Consumption data
Detailed depiction of individual loads/data

Process equipment:

Functions
Interfaces
Areas of application
Ongoing communications (suppliers)

Benchmark for creating concepts:

Arriving at solutions for specific projects
Enquiry process
Clarifying the standard of current technology
Coordination of project content

Checking integration / layout:

Detailed coordination
Planning security
Compatibility
Coordination for specific sectors

Bid process / documentation:

Coordination & preparation
Project communications
Consistent
Phased arrangement

Design base:

General project information
General site information
Specific plant parameters
Communication interfaces

Functional specification:

Mechanical plant functions
Control engineering functions

Existing plant / equipment:

Records of measurements/photos
Custom documentation
Acceptance of draft project

3D image documentation:

Based on 3D scan technology
Project content and result
Custom preparatory work

Description of plant:

Overview of plant
Brief description
Detailed description

Safety requirements documents:

Risk assessment
Considerations regarding safety requirements (dust explosion)

Retrofits:

Preparations for control engineering and mechanical retrofits
Custom preparation

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3D scan technology at AZO

Criteria and Solution

Measuring distances using a folding ruler – calculating pipe circumference with a tape measure – images for orientation – laborious creation of sketches by hand

In the past, the effort of recording dimensions on site for existing buildings and installations was often a time-consuming process which left system designers with a degree of uncertainty in the positioning of equipment.

This process has been significantly simplified through the acquisition of a 3D laser scanner. Using a laser-based scanning system, it is now possible to generate a high quality record of dimensions in the form of a point cloud which, with the support of image material, offers improved visualisation of the installations, building, equipment and interference contours.

Technical hardware and software

The AZO 3D scan equipment is easy to transport and can also be taken onto an aeroplane as hand luggage.

Our laser scanner - LEICA BLK360

Laser class 1
Protection class IP54 (IEC 60529)
Replaceable Li-ion battery
Field of view: 360° horizontal / 300° vertical
Visibility: up to 60 m
360,000 points per second
Accuracy: 4 mm at 10 m / 7 mm at 20 m
Temperature ranges: +5°C - +40°C

The 3D laser scanner is positioned on a tripod at the location to be scanned and controlled via an iPad.

Thanks to a range of scan qualities, there are options for scanning different scenarios as desired. THE RESULT is a coordinate-based point cloud including 360° images for improved visualisation.

Once the point cloud has been processed, we make the file available to you via a private SharePoint; we are happy to advise you on the next steps. You can examine the result yourself using a freeware solution from Autodesk, and contact us at any time.

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Integration Processes – Added value

From your perspecive

Image documentation of your existing installation (as-built)
Point cloud for next processing steps
No need for additional measurements when positioning components
Save time/costs using explicit recording instead of manual measurements
Incorporation of point cloud into VR technology & Navisworks
Implementation of 3D models in your existing system/building

From AZO's perspecive

Rapid overview of the installation for our employees
Minimise errors by recording the environment
Overlaps with other equipment avoided (e.g. ventilation ducts)
Improved certainty for system design
Dimensions can be measured at any time

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VR Technology from AZO

Requirement / Situation / Design criteria

The current state of the art increasingly involves the use of CAD to design and document installations. Exporting different drawing views from the 3D model gives the customer an understanding of the installation situation and components.

Being able to see the individual structures and backgrounds for the installation makes it easier for designers and project managers to get a mental image of the overall system. However, it is difficult for many of our customers to imagine the respective dimensions and components.

Therefore, at AZO we frequently ask the following questions:

How do I communicate the contents in “layman’s terms” (for work colleagues, partners etc.)?
How do I communicate the contents to “third parties” (subsuppliers, construction, etc.)?
How do I communicate the contents to “decision makers” (management, investors, etc.)?

The solution

Using our VR technology, it is possible to load and visualise many 3D formats using a mobile or stationary unit.

Dimensioning of components and plants
Completion understanding for production processes
Orientation in the plant and in own production area
Planning of material flows, personnel routes and general production

By generating a virtual environment on the basis of real dimensions, you can visualise the content of the installation and its environment more accurately.

Investigate installations/components/buildings etc.
Experience plant technology/process technology etc.
Explore

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The hardware and software

Owing to ever increasing enquiries and use of VR technology, AZO has three different types of VR goggles:

HTC VIVE PRO SPEC (stationary, wireless version at AZO’s premises)
HP Windows Mixed Reality headset (portable, wired version)
OCULUS QUEST (portable, wireless version)

Each of these units has an associated Mixed Reality controller for movement, inspection and control in the virtual environment.

The models can in some cases be loaded directly into CMC ViewAR software or converted into the right format using various programs. Even the depiction of point clouds from 3D scans can in some cases be loaded directly and combined with our models.

To keep our customers safe during their individual VR tours, we use automatic boundary detection in the range of movement in order to avoid real-world obstacles such as tables and chairs.

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Integration processes

The process map shows how integration of the 3D models into virtual reality works. In principle, it is possible to incorporate different CAD files, including those without AZO components.

Architectural services
Processing plants (other project participants)
Systems for peripheral processes
Main and additional components (space requirement)
Point clouds from 3D scan (actual status of your installation/building/equipment)

This equipment is the perfect tool for illustrating and presenting, and generally as a visual basis for discussion independently of the value creation chain. The cross-process visualisation allows you to see the overall extent of your designs.

Added value for stakeholders

Benefits for our customers:

Mapping/assessment of installations and operating concepts
Timely and informative involvement of own employees (regardless of workplace)
Promotion of internal acceptance in the case of potential new investments
Counteracts potential (negative) preconceptions

Benefits for AZO:

Improved customer understanding with direct communication
“Comfort zone” for the customer
Ideal basis for project
Ideal basis for discussion for all project participants (and other stakeholders)
Range of variants
Basis for determining requirements
Rapid reaction time
Location-independent