In close collaboration with Seprify, a spin-off from the Universities of Cambridge and Fribourg, Helbling managed and executed the development of a scalable pilot plant for producing a novel cellulose-based white pigment. The chemical process includes all essential unit operations such as dosing, reaction, post-processing and wastewater treatment.
The aim was to deliver a semi-automated, safe and reproducible pilot plant within a fixed budget – from concept development to successful commissioning.
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Key Figures
- Scalable pilot plant for a novel cellulose-based white pigment
- Chemical batch process from dosing and reaction to wastewater treatment
- Commissioned 12 months after project start
- Plant footprint of 150 m²
- Production capacity of 14 kg of product per day
- Semi-automated batch operation control with Beckhoff TwinCAT PLC & HMI
Our Contribution
Helbling and Seprify jointly planned, managed and executed the development of the complete plant. Helbling was responsible for the engineering, from concept development to successful commissioning and the training of specialized personnel.
The reactor design was optimized using CFD simulations to ensure efficient mixing and heat transfer. A robust automation concept with HMI control enabled safe and reproducible operation. This integrated approach enabled a seamless transition from lab to pilot scale.
- Project management and systems engineering
- Development of the pilot plant concept
- CFD-based design of the mixing and heating system
- Specification and sourcing of a corrosion-resistant reactor
- Development of an automation concept including safety architecture
- Engineering of the control cabinet and sensor interfaces
- Software development in Beckhoff TwinCAT including HMI
- Configuration of all sensor and actuator interfaces
- On-site assembly support, FAT and SAT with suppliers
- Material compatibility testing in the Helbling chemistry lab
Outcome
The pilot plant was successfully commissioned 12 months after project start. It now enables Seprify to produce cellulose-based white pigments at pilot scale for their clients and provides a flexible platform for process optimization and tests with alternative raw materials. Thanks to close collaboration between all principal partners, the project was delivered on time and within budget.
Contact
Cases
Internationales Unternehmen der Papierindustrie – Analyse des Dampfsystems
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Cases
6-Streifenausbau Aarau Ost – Verzweigung Birrfeld – Bauherrenunterstützung
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