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7 steps to a successful partnership
We offer a tailor-made solution for every customer, which requires a clear plan of action. We always start with our 7 basic steps.
1
Offer
For each project, we work with the customer to find the most efficient solution for his production process.
We try to describe the customer’s question as clearly as possible.
During this phase, we may draw up a 3D preliminary project.
2
Fixing the concept
Our presales engineers further develop the proposal conceptually. We discuss this with the customer and make adjustments where necessary.
At the customer’s request, 3D, robotic and virtual reality simulations can already be performed in this phase, as well as flow simulations in order to offer the most successful solutions.
In this phase, we also set delivery deadlines and other agreements.
3
Engineering
In our engineering department, no fewer than 100 colleagues work together according to the principle of mechatronics, taking another step towardsIndustry 4.0 every day.
Ceratec has four specialized engineering offices, each staffed by a multidisciplinary team of experts, engineers, draughtsmen and programmers.
These engineering offices are supported in their main tasks by a team of machine safety experts, as well as CAD/PLM specialists…
- Process engineering: Our specialists in thermal processes (drying plants, kiln technology, process control), railcar transport systems and bulk transport of clay products.
- Material handling and robotics engineering: Product handling, robotics & 3D vision, on programming - Conveyors - Cranes
- Intralogistics engineering: Shuttles & logistics solutions - AGVs - Software applications (WCS)
- Electrical design engineering
4
Manufacturing
Starting from a complete 3D production file, the manufacture of the plant parts can begin. Ceratec has a wide range of machinery at its disposal, enabling it to manufacture most of the parts it needs in-house.
- Electrical cabinet construction workshop
- Metal workshop and plant construction
Starting from a complete 3D production file, we begin manufacturing plant components.- Machining (link to
Ceratec’s extensive machinery enables it to manufacture most of the parts it needs in-house:- We CNC turn metal
○ Up to 400 mm diameter: max. length 6000 mm
○ Diameter 401-710 mm: max. length 3000 m - We CNC-mill lengths up to 7000 mm; widths up to 2200 mm; heights up to 1500 mm.
- We CNC turn metal
- Welding workshop
Our team of 20 experienced welders is led by an IWE (international welding engineer). They work mainly with semi-automatic machines, but are able to apply all welding techniques to perfection. At Ceratec, each welder makes his or her own part.
Our welding work is already EN1090-compliant, and the official certification procedure is underway.
- Machining (link to
- Subcontracting – steel structures for B2B partners
5
Assembly and testing
Once the necessary preparations have been completed, we start wiring the power distribution cabinets or MCCs based on the drawn plans.
We often use these modular and flexible systems for this purpose:
- Siemens Sivacon S4/S8
- Schneider PRISMA
- CUBIC: can be fitted with equipment from various brands
- Rittal: can be fitted with different brands of equipment.
In a separate test area, all cabinets are thoroughly tested before leaving for the customer’s premises.
Once all the parts have been manufactured or purchased, we start assembling and wiring the system in the large assembly hall:
- 10 m height under the overhead crane
- Overhead crane lifting capacity: 25 tonnes
For facilities that have to meet stringent hygiene, safety and health requirements (e.g. pharmaceutical or cosmetics companies), a cleanroom has been set up.
We then test the control system and programming down to the last detail, so that commissioning takes as little time as possible.
The final stage is the FAT (factory acceptance test) with the customer.
We insist that the employees who carried out the indoor installation install and commission the system on the customer’s premises.
6
On-site installation
During this phase, the fitters go to the customer’s site to assemble the complete installation, wire it up and commission it. During the start-up phase, Ceratec monitors the entire process until the system is running smoothly, and then carries out a SAT (site acceptance test).
7
After-sales service
Ceratec’s after-sales service team is an integral part of our role as a complete supplier. It’s even a business unit in its own right within our organization, because customers can continue to count on Ceratec’s support even after each installation has been commissioned.
For both preventive and accidental maintenance, our technicians are available 24 hours a day to assist the customer. Good spare parts management supports this service.
