Engineering

Engineering

We also support you in expanding and updating your system

From the development of concepts to detailed design FÜLL is your reliable partner for your engineering projects. Whether your products need to be stored, agitated, conveyed, dispensed or all of these together: you can count on FÜLL’s skilled team of engineers and technicians for design, programming etc. We will develop a solution together adapted to your requirements and meeting your expectations.

We select from a range of different basic system configurations, depending upon the desired production capacity, the number of characteristics of you base components, available space and other criteria.

Nevertheless, each basic system can be modified and adapted to meet you specifi needs. Regardless of whether the installation is to be integrated into an existing production line or installed as a stand-alone solution, no matter whether you want fully automated or manual dispensing, integration into an enterprise Resource Planning System or a completely non-interfaced solution – our products stand for reliability and flexibility.

  • Do you plan to extend your plant?
  • Or do you want to bring your plant up-to-date?
  • Or do you have a completely different task? – If so, just contact our sales department.

Consulting services by FÜLL

Benefit from 45 years of experience and more than 2.200 customer-specific designed plants and storage systems.

  1. Analysis of your products
    • liquid raw materials
    • pastes
    • intermediates
    • additives
    • etc.
  2. Analysis of your current situation regarding work and material flow in your production
  3. Comprehensive planning for the optimization of production, storage and dispensing concepts for just in time production and effective quality increase
  4. … or step by step suggestions for the improvement of partial optimization for short-, mid- and long-term investments
  5. Design of smallest systems for laboratory use
  6. Systems for mid to high throughput
  7. New developing and modification of existing storage and plant concepts for implementation into existing systems
  8. Dispensing systems for different performances – combined with your existing storage systems or a new taylored system with expansion possibilities
  9. Programming of your desired functionalities into our software – including interfaces to superordinate software like ERP systems
  10. Consulting on periphery like colormatching systems and homogenization of your products
  11. Mounting, functional test and operator training for every plant designed by FÜLL
  12. Assistance for client ROI calculations with FÜLL-Investments
  13. Calculations according to realistic client budgets

Plant extension

An increased production, higher production depth or extra products for your portfolio;
These are all good reasons to extend your FÜLL-plant.

The modular concept behind FÜLL-plants allows for uncomplicated installation of extra valves, pipes, hoses and storage containers into your existing system.

Naturally we can bring your plant up-to-date when we extend it.

 

Process development

Do you want to form your production or processing future-oriented?

We made us a name as a think-tank due to our experience in process automation.

We assist you as a professional partner from conceptional design, procedural lay out design and construction to developing completely new systems and machines.

Naturally we develop the process targeted to your wishes and requirements; Only this way the new fits smoothly into the existing.

Retrofit

 

Make Do and Mend – Retrofit

Retrofit” or “Revamp” is modernization of plants and systems as a cost-effective alternative to a new constructed system. Often only a few aspects of FÜLL systems require improvement after a long operating life. Like for new systems, the plant safety is the outmost important thing to keep in mind.

For this reason, FÜLL offers modernizations individually and consults with all decisions to make. The final degree of modernization will be defined together with the customer.

The following will give an insight to the possibilities, that can be executed.

Electric control

The centerpiece of the electric control is the computer, which saves all important system parameters as well as administrating formulations, job data and protocols. But also a computer in industrial quality is aging and should be replaced and its software updated.

The development in automation goes forward in a speedy manner and the trend towards ethernet communication is naturally part of the current controls offered by FÜLL. New possibilities for remote maintenance via internet and a secure VPN tunnel (Virtual Private Network) are associated. On this way FÜLL service personnel can analyse problems down to the PLC (Programmable Logic Controller) and render assistance.

Valve actuation

The valves used in the dispensing centers FS 182.2 and FS 2005.2 series are controlled by servo drives. They guarantee a highly dynamic and precise dispensing process. The exact valve opening allows for optimal adjustment of the dispensing parameters or rather allow the system to determine and optimize the parameters automatically by the dispensing software CALIPSOPRO.

Those new drives supersede inconvenient initialisations after power fail restarts.

Valve actuator

The valve actuator is the frequently used construction group in the dispensing center, because all valves are opened and closed continously. A fast and precise stroking is essential, because not only the operning and closing speeds are relevant, but also the compliance with the correct stroke for coarse and fine dispensing are critical.

Valve platform

The dispensing valves in the most gravimetric dispensing centers are installed on a valve platform, which is actually a powered sledge for positioning the currently required valve under the valve actuator. the platforms servo drive is of the same type as the the one used for the valve actuation, simplifying spare part inventoring.

A fast and precise positioning at a speed of generally 250 mm/s reduces dispensing times considerably. This drive also keeps its current position “in mind” after a power fail restart. This significantly simplifies system restarts after emergency stops or maintenance, too.

Valve cleaning unit

The modernization or conversion with an automatic valve cleaning unit is naturally also a retrofit solution. The valve cleaning unit is the perfect upgrade for the dispensing center, when it is not possible to manage manual cleaning the valve heads during production peaks. It’s a reliable protection against dirt and migration of adherent substances. It also frees extra capacities, because it safes a lot of time for the operator.

The closed valve cleaning systems combines chemical with mechanical cleaning. The valve heads are cleaned with a product-compatible cleansing agent by rotating brushes. The cleansing agent is used in circulation to reduce consumption.

At an already used valve cleaning unit, the wear parts like brushes and hoses are inspected after long time use.

Wear parts

Nevertheless sealings and hoses are exposed to chemical and mechanical stress and therefore to be seen as the main wear parts in every system. A cracked hose can disrupt production for hours and wastes personnel resources. These kind of wear induced problems can be better seen by externel personnel, wich is not working every day at the particular system.

Naturally FÜLL Systembau GmbH only uses high-quality hoses, to reduce maintenance.

Therefore our remark:

FÜLL offers maintenance contracts for dispensing and storage systems.

Safety

Operators safety is the highest priority to FÜLL. All changes and enhancements are made according to the newest standards being effective.

But FÜLL never loses track for the main objective – the cost-effective modernization. Sometimes it is more cost-effective to easily exchange construction groups, because complex modifications imposed by technical supervising institutions may be higher in price.

FÜLL systems follow a consequent systematic design to allow for both possibilities.

Gladly FÜLL evaluates the safety of your system, makes recommendations and consults for a suitable solution.

Worth knowing / Machines from other manufacturers

Naturally FÜLL Systembau GmbH offers retrofit solutions for third-party products, also.

This way the familiar system design can be sustained and the high-quality FÜLL technics optimally prepare the production for the future.

 

Rohrleitungsbau

Design and construction of pipeplines are important parts of process plants. These works need to be carried out by qualified expert staff. Our engineers and technicians possess the required experience and knowledge to design the pipings according to applicable rules, laws and regulations tailored to your process requirements.

FÜLL minimizes the installation troubles for the customers by preassembling the pipeline at our site in Idstein. Consequently welding is left out at customer site. This comes in handy for facilities in hazardous areas, where welding would disrupt the whole production. A considerable reduction of the construction time and increased safety for your employees are the results.

As a specialized company according to §19 I WHG (Water Resource Act), FÜLL’s pipeworks naturally fulfill the current standards and are manufactured by certified welders according to EN 287-1 certification.

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