High-quality engineering solutions in the manufacture of machines and equipment are evaluated by whether they operate reliably under real conditions, meet the requirements of the specific industry, and are easy to maintain. For this reason, at Stabilengineering-Alfa the work process is structured into clear stages that ensure control from the very first discussion, traceability during execution, and a reliable start during commissioning.
What does a complete service mean for us?
Stabilengineering-Alfa designs, manufactures, delivers, installs, and commissions equipment and complete technological lines for the food, biotechnology, chemical, and pharmaceutical industries, with solutions tailored to the client’s requirements and the applicable regulatory provisions.
The process is applicable both to the construction of new production facilities and the implementation of complex lines, as well as to modernization projects, expansions, and the integration of new equipment into existing production areas. The same approach also applies to individual custom-made equipment when there is technological specificity, space limitations, specific hygiene and cleaning requirements, or a need for control and traceability of the quality of the finished product.
The key element in this model is consistency. The preliminary analysis defines realistic requirements. The design process transforms them into specific engineering solutions. Production follows the approved documentation and established procedures in accordance with the implemented ISO 3834-2 and ISO 9001 systems. Delivery and installation ensure trouble-free commissioning and complete the cycle of the work process. After that, our team remains committed to warranty and post-warranty service, because for production facilities, process continuity is critical.
Stages of work at Stabilengineering-Alfa
Stage 1: Initial contact and clarification
The first stage involves structuring the task and describing it from a technological perspective. We clarify the parameters and the main steps of the process. We determine the required capacity and productivity.
We become familiar with the available space and its limitations – dimensions, heights, and access points. We also consider any equipment that must be retained or integrated. We clarify the hygiene and cleaning requirements. We discuss the desired deadlines and the specific installation window, especially when production cannot be stopped for a long period of time.
For the initial discussion to be as effective as possible, it is useful for the client to have answers, or at least preliminary guidance, on the following questions:
- What product will be manufactured or processed?
- How does the main technological process take place?
- What is the desired capacity?
- Is future production expansion planned?
- What premises are available, and what are their main dimensions and heights?
- Are there any restrictions regarding access, installation, or equipment servicing?
- Is there existing equipment that needs to be integrated?
- What are the hygiene and cleaning requirements for the system?
- Are there any specific safety or process control requirements?
- What is the planned implementation timeframe, and is there a fixed period for installation?
Stage 2: Process analysis and feasibility assessment
When the project requires it, we carry out an on-site inspection to observe the actual flows, sanitary zones, and practical limitations related to installation and servicing. This stage is important because many problems arise due to a mismatch between technology, space, infrastructure, and day-to-day operation.
In parallel, we analyse the work stages, the critical points of the process, the limitations, and the objectives that the client needs to achieve. At this point, the objectives are usually specific: higher efficiency, fewer downtimes, consistent quality, safety for personnel, and compliance with the standards of the respective industry. The outcome of this phase is a clear basis for the development of a concept.
Stage 3: Concept and technological solution
Based on the information collected, we develop a concept and a technological solution. At this stage, communication with the client is a direct part of the engineering process, because the proposal must meet both the technological requirements and the real production priorities. We present the solutions clearly and with justification, so that their logic is visible, as well as the way in which they will be integrated into the existing production process.
After all points have been finally clarified, we prepare a final offer based on the agreed approach and the expected results. This is the moment when the project moves from concept to confirmed implementation.
Stage 4: Technical specification and coordination with supporting designers
In new facilities, reconstruction projects, and complex production lines, coordination with other designers is often required. In such cases, we prepare a technical specification for the supporting teams so that the technological requirements are properly defined and coordinated with the infrastructure, premises, and installations.
The purpose of this stage is prevention. When the technological conditions are formulated and synchronized on time, this prevents unforeseen on-site changes, conflicting solutions, rework, and delays that would otherwise appear during installation or initial start-up.
Stage 5: Engineering and Design / 2D and 3D
This is the stage in which the concept becomes a project that can be manufactured and implemented. Stabilengineering-Alfa has a team of highly qualified engineers in different areas of specialized equipment, including mechanical designers, project engineers, and technologists. Projects are prepared either according to an assignment provided or jointly with the client.
In practice, engineering includes the structural solution, technological schemes, and the selection of materials and components within the requirements of the specific industry. An important advantage of this phase is visualization. We use modern software that allows us to provide detailed 2D and 3D visualizations of the designed equipment, so that the client can see what the equipment will look like and assess how it can be installed most effectively in their production environment.
Before proceeding with production, we carry out validation with the client. This means approval of the key decisions in terms of functionality, service, and integration, in order to minimize the risk of reworking in later phases.
Stage 6: Production and execution traceability
Production in our company is part of the complete service and follows the approved engineering documentation. We manufacture innovative, functional, and durable equipment from high-grade stainless steel, with each product being strictly customized according to the assignment and the client’s needs. This requires flexibility in execution and a strong focus on the quality of the final product, so that the equipment complies with the standards and requirements of the specific industry.
Traceability is ensured through control points during manufacturing, covering incoming material inspection, dimensional control and weld inspection, surface and assembly checks, as well as inspections of the completed product. At documentation level, this is supported by a set of technical documentation and by internal checks of the completed project, which ensure that critical parameters have been inspected and documented. All of this is carried out in accordance with the established procedures of the implemented ISO 3834-2 and ISO 9001 systems.
Specific machines and technologies play a key role in production, enabling accuracy, repeatability, and efficiency.
The laser cutting machine is based on Fiber laser technology and allows high-quality cutting of stainless steel, ferrous, and non-ferrous metals with nitrogen or oxygen. It is equipped with a 2 kW optical laser source. It allows cutting of sheet material up to 1500 mm by 3000 mm, as well as the processing of pipes and profiles with a maximum diameter of up to Ø250 and a maximum length of up to 6000 mm.
The configuration includes software that optimizes the positioning of the components on the material for maximum utilization and minimum waste. The availability of stainless steel in stock further shortens the lead times for component production.
For sheet metal bending, we use a CNC-controlled hydraulic press brake with a capacity of 135 tonnes, a working length of 3050 mm, and a distance between the columns of 2600 mm. The control is carried out along 3 axes and includes a graphic touchscreen and bending simulation.
The equipment has a motorized back gauge with support, a manual WILA anti-deflection system for bend compensation, and a EURO tool clamping system, which is important for accuracy and repeatability in series operations.
When work with cylindrical shells and cones is required, we use a 4-roll plate bending machine designed for bending metal sheets and plates into cylindrical and conical shapes. It ensures a high degree of process control, the possibility of pre-bending and finishing bends, as well as calibration. The parameters include a maximum bending length of 3100 mm and a maximum sheet thickness of 8 mm.
For bending pipes and profiles, a 3-roll profile bending machine is used. It is applicable to different cross-sections and sizes, including solid and rolled profiles. The machine allows bending into circles, arcs, and serpentine shapes and is equipped with a modern control system for accuracy and repeatability.
For cutting sheet material into simple geometric shapes, we use a CNC-controlled hydraulic guillotine shear with a D-Touch 7-inch touchscreen and central adjustment of the blade clearance. It has a maximum cutting width of 3100 mm, a maximum cutting thickness of 6 mm for carbon steel, and 4 mm for stainless steel.
For manufacturing round and conical bottoms used in tanks, cisterns, and vessels, we have a sheet metal flanging machine that combines cutting and flanging processes in a single operation and optimizes the production time of the components. The parameters include a maximum blank thickness of up to 6 mm for carbon steel and 4 mm for stainless steel, as well as a maximum diameter of up to Ø4000 mm.
In welding, which is essential for stainless steel equipment and pipelines, we offer both manual and automated execution.
We have a sheet welding machine for automatic welding of longitudinal but welds up to 2000 mm in length. It is applicable for joining stainless steel sheets and shells with a thickness of up to 5 mm, as well as a welding column with a rotator for circumferential but welds with a working height of up to 2000 mm. It is also used for welding shell-to-shell and shell-to-bottom or shell-to-cover joints in vessel manufacturing.
For pipe joints, we have equipment for automatic orbital TIG welding of stainless steel pipes with a diameter of up to DN 250, equipped with oxygen meters to ensure the protective argon atmosphere, as well as controllers that can generate a unique protocol for each weld and record the process parameters. Manual TIG and MIG/MAG welding is performed according to welding procedures developed together with a certified International Welding Engineer, and our team is trained and certified in accordance with regulatory requirements.
For machining, we operate in a specialized production area equipped with universal lathes, milling machines, drilling machines, tooling, and fixtures for the precision machining of components with different shapes and configurations. Turning of components with a diameter of up to Ø1500 and a length of up to 3000 mm is possible, as well as the processing of individual components or small series.
As part of the product completion process, inspections are carried out before shipment to confirm compliance with the documentation and readiness for delivery. A standard documentation package is provided with the equipment, including a technical passport, inspection reports, and declarations.
Stage 7: Delivery, installation, and on-site integration
After production, delivery and installation of technological equipment and pipelines follow. The team of installers, fitters, and welders performs positioning, assembly, and levelling of the equipment. An essential part of this stage is also the construction and installation of various types of water pipelines and air ducts.
This service is also offered independently when the client specifically needs the installation of pipe systems without the manufacture of new equipment. A supervisor monitors the quality of execution at every step, and, when necessary, the presence of an electrician and/or the project design engineer is provided.
Installation management is based on a pre-agreed schedule, coordination with the client’s team, and compliance with safety requirements. The aim is to minimize downtime and ensure proper integration into existing lines. Within this stage, adjustments and test cycles are carried out, after which validation is performed against the agreed result so that the implemented solution operates in the actual process.
Stage 8: Training, documentation handover, and service
After start-up, training of the personnel is carried out when necessary. In practice, it covers the operator’s part related to correct operation and basic maintenance, so that the client’s team can work confidently and predictably with the equipment. At the same time, the documentation is handed over. As standard, it includes a technical passport of the product, consisting of technical data and instructions for operation and maintenance of the specific equipment, test reports, and applicable declarations.
We understand that production facilities need to operate without interruptions, which is why we offer warranty and post-warranty service. The team is available when repair or preventive maintenance is required. The products are provided with a 12-month warranty, and when necessary, an on-site visit is carried out for diagnostics and troubleshooting.