Industrial Plant Solutions
Industrial Plant Solutions
Custom Plant Solutions for Your Production of Tomorrow
Complex production processes require flexible and intelligent solutions. 3defacto develops and delivers turnkey production systems tailored precisely to your requirements and spatial conditions – from process analysis and system planning to commissioning.
Whether it’s a completely new installation, the expansion of existing lines, or the integration of individual modules: Our team of experienced engineers and project managers ensures seamless implementation – efficient, economical, and future-proof. Every solution incorporates 25 years of expertise in special-purpose machinery and automation technology.
Your project – our plan
Our Service Portfolio
- Planning, development, and implementation of complete production lines
- Integration of automation and material flow systems
- Implementation of individual requirements such as ergonomics, cycle times, or energy efficiency
- In-house software development, switchgear design and production
- Training, support, and after-sales service from a single source
Cross-industry system solutions
Scalable, efficient, and tailored to your processes
Industries we serve:
- General and special-purpose mechanical engineering
Realization of customized machinery projects based on specific client requirements. - Automotive and Automotive Supplier Industry
Planning, construction, and commissioning of prepolymer systems, tank farms, and process solutions. - Construction materials industry
Development of robust machines for the production and processing of construction materials. - Chemical industry
Specializing in polyurethanes, adhesives, prepolymers, paints, and coatings. - Household Appliance Industry
Especially for processing plastic-based systems, 3defacto delivers storage, transport, and dosing systems in cooperation with leading casting machine manufacturers. - Plastics Processing Systems
Planning, construction, and operation of prepolymer solutions, tank farms, and process systems. - Food industry
Systems designed to meet strict hygiene and safety regulations for food production. - Pharmaceutical industry
Development and implementation of machines and systems that meet the highest standards of pharmaceutical production. - Bulk material processing industries
Providing conveying and processing systems for efficient bulk material handling.
Modules from Dosing to Control
Industrial plant technology that makes processes measurably better
The project requirements are handed over in an initial meeting. 3defacto creates a process flow diagram that incorporates many years of experience. The optimal production process, combined with low personnel and energy requirements, is part of a 3defacto proposal concept. The concepts are always based on a modular design of the process engineering components. Naturally, all systems are delivered with control cabinets and software modules from our in-house electrical department. This ensures the highest standards in terms of sustainability, durability, and quality.
All plant modules from 3defacto are assembled, tested, and commissioned in-house. Only after all internal tests have been successfully completed are the modules shipped to the customer. Once on site, the modules are mechanically and electrically connected and commissioned within a very short time. With NEXUS, we enable our customers to implement preventive maintenance of the supplied systems.
Examples of implemented systems
The system consists of the following main modules, which can be combined individually:
Tank Farm
Safe storage of flammable or water-polluting liquids
3defacto designs and builds above- and underground tank farms for the safe storage of liquid, flammable, or water-polluting substances such as polyol, isocyanate, or pentane. As a WHG-certified specialist company, we meet all legal requirements – from layout planning to containment systems and safety or monitoring technology.
Key Features
- Design compliant with WHG, BetrSichV, and TRwS
- Above- and underground tanks up to 60 m²
- Equipped with leak detection, inert gas blanketing, or a gas pendulum system
- Integration into higher-level control and automation systems
- Media-specific design for aggressive or sensitive liquids
- Customized planning based on storage volume, medium, and location
- Optional temperature control
- Pump stations designed for process requirements
- Truck loading
- Pressure unloading
- Integrated filtration systems
Prepolymer Systems for Thermoplastic Polyurethanes
Stable processes thanks to optimally conditioned media
Heating, mixing, cleaning – our process modules ensure consistently high quality through conditioned input media and clean process environments. This ensures long service life for both your technology and your products.
The prepolymer system from 3defacto enables the processing of polymers – consisting of polyol, isocyanate, and additives – in liquid or bulk form to a consistently high quality level. Mixing, heating, and degassing steps are fully automated and precisely adapted to the material properties – ensuring constant product quality and maximum process reliability.
Key Features
- Modular system for integration into existing production lines
- Continuous or batch operation
- Real-time temperature control
- Optional vacuum degassing
Prepolymer Laboratory Reactor
3defacto’s innovative prepolymer lab reactor includes all the functions of a large-scale system. The reactor volume is 20 liters. It is used in research and by manufacturers of wheels, rollers, or elastomer dampers for scale-up and formulation development. The system is equipped with vacuum, temperature control, stirrer, sensors, and advanced automation.
The lab reactor is also used by our customers for training purposes in addition to R&D.
Key Features
- Custom design for liquids, pastes, or solids
- Chemically resistant surfaces and easy-to-clean construction
- Connection options for power, compressed air, gas, or vacuum
- Integration of small reactors, stirrers, or dosing systems possible
- Optional with fume hood, safety glazing, or extraction system
- Optional with load cells, data acquisition, and control panel
Conditioning Station
These stations heat media to process-specific temperatures and maintain them constantly. Stirring and mixing systems can also be integrated.
Key Features
- Temperature control with tight tolerances
- Designed for various media: viscous, abrasive, temperature-sensitive
- Interfaces to dosing and reaction modules
- Optional with logging and alarm management
Cleaning Station
Our cleaning stations ensure hygienic and product-safe processes – especially for product changes or in sensitive industries such as medical or food processing.
Key Features
- CIP-/WIP-capable (Cleaning/Washing in Place)
- Programmable cleaning cycles
- Compatible with various cleaning agents
- Documented cleaning for GMP or FDA compliance
Dosing Station
Precise dosing of liquids and solids
Whether liquid or solid – with 3defacto dosing stations, raw materials are dosed safely, precisely, and automatically. The stations are modular and adaptable – for batch or continuous processes. Each unit covers unloading, storage, mixing, and preparation of materials.
Functionality
Liquids are pumped via diaphragm pumps into tempered feed tanks. Recipes are stored in the control system and allow fully automatic dosing into mobile or small containers. Static or dynamic agitators ensure homogenization.
Solids are fed via docking stations (drums, containers, Big Bags) into a buffer tank and precisely dosed via micro-dosers – directly or through a feed container.
Options for Liquids
- Heated/cooled feed tanks
- Filling into mobile containers or IBCs
- Integration into reactor or cleaning systems
- Continuous dosing with static mixer
- Optional water treatment integration
Options for Solids
- Drum or container tipping stations
- Big-Bag docking stations
- Pneumatic conveying into reactors
- Customized machines on request
Key Features
- Precise dosing, even for smallest quantities
- Automated operation with recipe management
- Homogenization via customized agitator systems
- Low-dust solid discharge
- User-friendly control system
- Seamless integration into the overall process
Drum Tipping Station
3defacto’s drum tipping station enables ergonomic and safe discharge of liquid or viscous media directly into the process. The drum is emptied via an electrically or hydraulically powered tipping mechanism – either manually or fully automated. Optional features include level sensors, weighing systems, or docking components.
Key Features
- Safe and user-friendly handling of standard drums
- Electric or hydraulic drive
- Compatible with spill trays, pumps, and piping
- Optional integration of load cells or empty-level sensors
- Suitable for food, chemical, and pharmaceutical sector
- CIP-capable and documented cleaning in compliance with GMP/FDA
Mixer
Custom-configured for optimal mixing results
Our mixing machines are tailored for dosing and production processes involving precise, homogeneous blending of liquid raw materials or additives. Whether for small or large volumes – the systems are designed per project and support both batch and continuous operation.
Functionality
Liquids are transferred from feed tanks via dosing pumps. Homogenization is achieved with agitators specifically designed for the medium, viscosity, and density. Optional inline integration into a reaction system is possible for precise microdosing. For continuous processes, static mixers are used.
Options & Integration
- Inline integration into reaction systems
- Water treatment system integration (e.g. for demineralized water)
- Filling into IBCs or mobile containers
- Batch or continuous inline operation
- Stand-alone or integrated into dosing stations
Container Station
The 3defacto container station ensures safe placement, positioning, and discharge of IBCs or bulk containers in process plants. Whether for raw material supply, intermediate storage, or dosing – the station is tailored to medium, container size, and process workflow.
Key Features
- Suitable for all standard IBC formats
- Manual or automatic process connection
- Optional integration of pumps, agitators, or heating/cooling elements possible
- Load cells, level sensors, and drip trays available
- Media-specific configuration for chemical, food, or pharmaceutical use
- Optional with stainless steel piping, quick couplings and safety interlocks
Big-Bag Unloading Station (BBU)
The Big-Bag unloading station from 3defacto enables controlled, complete, and clean unloading of Big Bags – without manual intervention during the process. The system is suitable for various Big Bag sizes and meets high standards for safety, hygiene, and user-friendliness.
An integrated lifting and swivel mechanism positions the Big Bag precisely above the docking station. Automatic tightening of the outlet spout and the load-cell technology in the lifting frame ensure consistent material flow – even with difficult bulk materials.
Key Features
- Fully automatic discharge without manual steps
- Accurate positioning via guided swing movement
- Integrated dust protection system
- Compatible with standard Big Bag sizes (1,000–2,000 mm height)
- Optional ATEX-compliant design
- Suitable for food and pharmaceutical use (GMP/FDA)
- All-electric system – No pneumatic components required
- Low-maintenance and easy to clean
Applications
- Food, chemical, pharmaceutical, construction materials, plastics, and agricultural industries
- Everywhere bulk materials need to be transferred cleanly and safely into the process
Software
Good. Better. Optimal.
3defacto NEXUS IoT Platform – Your System, Live and Connected
Key Features:
- Live monitoring of production status, capacity, and OEE
- Alerts via app and email in case of malfunctions or maintenance needs
- Digital reports, log files, and camera access
- Direct access to customer service and spare parts
- Secure remote access via VPN (ISO-certified)
Prevent Downtime Before It Happens
NEXUS detects potential issues before they cause failures. Stay ahead of problems and avoid unplanned stops.
Customer Service
Reachable. Competent. Straight forward.
Your direct line to our customer service!
The service of 3defacto GmbH is available on weekdays between 8:00 am and 5:00 pm (GMT+2). We guarantee a response within the business hours of four hours. If available, please have your project and order number ready.
Service hotline: Service
3defacto offers you comprehensive maintenance as well as a fast and uncomplicated service in case of problems. Our services in the specialist area of customer service are:
Maintenance
- Inspection of your entire plant / machine by our service technicians at your site
- Inspection of safety-relevant parts
- Maintenance plans specifically designed for your plant / machine
- Inspection according to water ressources law
- Precise documentation of the inspection
- Execution of machine / plant maintenance
- Plant optimization or repair of defects
- Optimization of energy efficiency
- Avoidance of downtimes and malfunctions
- Extension of the operating time of your plants / machines
- Request your customized solution now!
Technical support
- Fast solution of your problems
- Help with plant optimization
- Remote service
- Providing answers to any kind of questions
After-Sales-Service
Reliable – even after the project is complete
Even after your project has been delivered, we’re still here for you. Our After-Sales Service supports you with any technical or functional questions about your design or product. Whether you need adjustments, documentation support, or further development – our experts are ready to assist you reliably and efficiently.
Thanks to the long-standing experience of our teams, you benefit from direct points of contact and quick, qualified responses.
Get in touch
Want to get to know our engineering experts?
We offer new clients a detailed initial consultation – with a satisfaction guarantee.
Got a project in mind?
Let’s get started together and get in touch with our
contact persons.
Contact Person
Your direct line to us
Our contacts are happy to take time for your questions – personally, collaboratively, and on equal footing.
The INDUSTRIAL PLANT SOLUTIONS division is part of 3defacto
Learn more about our group and its wide-ranging capabilities.
