- 2,000 m² Innovation Center for Customized Separation Technology
- Process solutions with comprehensive testing prior to investment
- Comprehensive development & optimization, including scale-up and hygiene concepts
Flottweg Process Center
Custom process development & pilot-scale testing – from the lab to industrial-scale solutionsAt the Flottweg Process Center, you can develop your application in a practical setting, under realistic conditions, and before investing in a plant. Together with our specialists, we map out complete process flows, assess technical feasibility, and optimize every single step from the initial laboratory test to the pilot scale. Across approximately 2,000 square meters, state-of-the-art laboratory and testing facilities, as well as flexible setups, are at your disposal to specifically test and further develop customer-specific solutions.
Thanks to the close integration of the laboratory and pilot plant, you quickly receive well-founded and reliable results regarding the feasibility, design, and efficiency of your separation processes. This is how we lay the foundation for sound investment decisions, more efficient processes, and sustainable economic success.
Optimize your processes – minimize risks
An overview of our services
Feasibility and Scale-up Tests
From the laboratory to the pilot scale, we test the feasibility of your application under realistic conditions. You’ll receive well-founded results that serve as the basis for reliable transfer to industrial processes.
Process and Recipe Development
Together, we develop and optimize your processes. This results in a solution that is precisely tailored to your needs and enables the optimal design of your machines and systems.
Process Optimization
We analyze your processes to optimize them in terms of efficiency and performance.
Flexible Test Setups
Custom test setups enable tailored solutions for a wide variety of applications. Existing systems are flexibly combined and supplemented with additional equipment as needed.
Expert Insights
Stefan Bichlmeier: “Customers can validate their processes under real-life conditions and make investment decisions based on reliable data.”
Read the full interview here
Dr. Mathias Aschenbrenner: “The customer has always been the focus of the planning. The optimized flow of personnel and goods not only allows the customer testing to take place much more efficiently, but also enhances the preparation and follow-up processes.”
Read the full interview here
Stefan Bichlmeier: “The customer was always at the center of our considerations during the planning phase. On the one hand, we want to process the diverse products and applications in the best possible way in order to optimally serve the needs of our customers.”
Read the full interview here
From concept to solution
- Inquiry and Goal Definition: Your inquiry is received by the sales department, and we work together to define the specifics. During this process, we define the goal, product, scope, and appropriate level of testing.
- Laboratory and Analysis: Initial analyses and feasibility tests are conducted in the laboratory using small quantities. This allows for early conclusions to be drawn regarding material properties and process potential.
- Pilot Plant and Pilot Test: In the next step, processes are tested in the pilot plant under conditions that closely resemble real-world conditions. Here, various machines, process variations, and configurations can be tested.
- Analysis and Recommendations: Based on the test results, you will receive reliable recommendations regarding process performance, efficiency, and optimal design.
What does the Process Center offer?
The Process Center offers ideal conditions for flexible and practical tests. Thanks to the combination of modern infrastructure and short distances between all areas, projects can be carried out efficiently and developed rapidly.
Test Site & Areas
- 2,000 m² of testing, laboratory, and pilot plant space
- Three times the testing capacity compared to before
- Strict separation of clean and non-clean areas
Machines & Design Flexibility
- Permanent equipment: Sedicanter®, Tricanter® / Decanter (2-/3-phase), steep/flat cones, Sorticanter®
- Additional pilot and rental systems can be set up at short notice
- Micro-scale tests: Lemitec MD100 & laboratory belt press
- Flexible integration of additional equipment or components
Hygiene & Cleaning
- CIP system for automatic cleaning and for validating cleaning effectiveness as part of a FAT
- Industrial refrigeration and freezing capabilities
- Hot water supply for the entire process
- Wastewater treatment with neutralization
Laboratory analysis (short distances)
- Possible methods: Particle size analysis (laser diffraction), protein analysis (DUMAS), rheology / LUMisizer
- Advanced analytical services through partner laboratories
- Short distances between the laboratory and the pilot plant
Hygienic Applications in the White Area
The white area is designed for hygienic applications in the food industry. These include, in particular, processes involving vegetable proteins and starch, as well as applications in flour laboratories and food processing.
A special focus is placed on multi-stage process cascades, such as countercurrent protein washing. In addition, process steps such as pH dosing and mass balance monitoring via load cells can be specifically integrated. Complex process flows can thus be realistically simulated and precisely analyzed.
Combining specially designed systems, hygienic infrastructure, and flexible experimental setups makes it possible to test processes under realistic conditions and refine them in a targeted manner. This yields reliable results for the design and optimization of applications in the food industry.
Industrial Applications in the Black Area
The black area is designed for non-hygienic applications and features separate test areas as well as a customized media supply system. This allows industrial applications to be tested safely and under realistic conditions within defined parameters.
Key areas of focus include plastic separation as well as applications involving mineral oils and other industrial products. Even strong-smelling materials can be processed using special ventilation and exhaust systems.
The equipment and infrastructure in the black area make it possible to examine different materials under real-world conditions and to flexibly analyze and optimize processes.
Why Flottweg? - Your Benefits at a Glance
Flottweg combines technological expertise with practical process development. The Process Center is designed to test customer applications under realistic conditions, refine processes in a targeted manner, and develop reliable, cost-effective solutions based on these findings.
- High flexibility in experimental setups and process variants
- Process engineering expertise across all process steps
- By combining batch and, in partial cases, continuous operation, the system allows for flexible test conditions
- High process and tank capacities for realistic testing
- Customized experimental designs for targeted process optimization
- Various machine combinations and models are available, including decanters, separators, Sedicanter®, and Tricanter®