Process engineering
Smart engineering solutions for efficient and reliable industrial processes
At RvS Group, we transform technical challenges into safe, efficient, and reliable process solutions. As a specialist in the demanding food and pharmaceutical industries, we provide tailor-made engineering solutions from concept development to final commissioning. Our expertise connects your ambitions with a future-ready installation that performs reliably in practice.
Functional Design
A robust functional design forms the foundation for a reliable and efficient process. It translates technical requirements and production needs into well-defined specifications, ensuring seamless alignment between engineering, project execution, and automation.
A well-engineered functional design prevents issues in later project phases, reduces risks, and supports safe and continuous production.
Our Services
Our team supports customers in translating process requirements into a practical and executable design, including:
Developing P&IDs and instrumentation documentation based on process requirements and functional specifications
Defining material selections, pipe sizing, valves, and instrumentation requirements
Developing functional specifications for process equipment, including tanks, pumps, mixers, and heat exchangers
Developing operating concepts, alarm strategies, and fail-safe functions for safe and reliable operation
Verifying designs against applicable regulations, industry standards, and internal requirements, including ISO 9001, VDI guidelines, and EHEDG
Our approach
The team starts with a detailed process analysis, including production volumes, medium characteristics, and hygiene requirements. This input is translated into a functional design that defines all components, signals, and control logic required for reliable operation.
Scenarios such as start/stop sequences, CIP cycles, cleaning procedures, and emergency situations are analyzed and validated. The design is closely coordinated with project management, engineering teams, and the customer to ensure technical feasibility, safe operation, and successful implementation.
Customer benefits
Through our approach, a functional design delivers:
A fully documented design ready for detailed engineering and project execution
Reduced design and implementation errors, minimizing the risk of process disruptions and production downtime
Improved production installation reliability through clearly defined operating concepts and alarm strategies
Optimized safety, maintainability, and future expansion capabilities
Process Calculations
Process engineering calculations form the foundation of an efficient, reliable, and optimized process design.
By performing accurate calculations for flow, pressure, energy, and temperature, we ensure that piping systems, pumps, heat exchangers, and CIP systems are optimally designed and perform reliably.
This reduces the risk of process interruptions, equipment overload, and inefficient energy consumption, supporting safe and reliable continuous production.
Our Services
Our team performs technical calculations that are directly aligned with the design phase and real-world operational requirements. Our services include:
Flow calculations for product, water, steam, and CIP systems to ensure correct sizing and reliable operation
Pressure loss analysis in piping systems and optimization of pipe diameter sizing
Pump selection and pump curve analysis to ensure optimal performance and reliable operation
Heat capacity and energy balance calculations for steam and cooling water systems to optimize thermal performance
CIP flow and cycle time calculations to ensure effective and reliable cleaning performance
Developing process calculations and engineering spreadsheets to validate and support design decisions
Review and validation of calculations and design proposals
Our approach
We start by collecting process data, technical specifications, and design guidelines. We then perform scenario analyses and simulations to validate flow rates, pressure conditions, and temperature performance.
Results are validated for consistency, safety, and operational feasibility. Where required, alternative design solutions are developed and assessed before final recommendations are issued.
Customer benefits
Through our process engineering calculations, customers benefit from:
Reliable production with minimal process disruptions and downtime
Safe installation and reliable operation of piping systems, pumps, and heat exchangers
Optimized energy efficiency and reduced operational costs
Reduced risk of overpressure, cavitation, and inadequate cleaning performance
Validated design decisions based on engineering calculations, applicable regulations, and internal standards
P&IDs
Piping & Instrumentation Diagrams (P&IDs) form the foundation of safe, efficient, and well-controlled process design.
They provide a complete overview of piping systems, valves, instrumentation, and process flows, creating a clear foundation for engineering, automation, and operation.
Accurate and up-to-date P&IDs provide the foundation for engineering, project execution, maintenance, and reliable operation, minimizing risks related to production and safety.
Our Services
Developing complete new P&IDs for new installations, modifications, and engineering projects
Developing as-built P&IDs for existing facilities, including a complete documentation of piping systems, valves, and instrumentation
Implementing small modifications and updates to existing P&IDs
Our approach
We use AutoCAD Plant 3D to create accurate and structured P&IDs. Component information and documentation can be directly linked within the P&ID environment. During on-site surveys, we verify tag numbers to ensure complete and accurate registration of all equipment and instrumentation.
We start with available drawings, specifications, and existing documentation. If required, we perform a complete on-site survey of the facility. All collected information is translated into accurate and structured P&IDs, including correct piping, instrumentation, and process flows.
Customer benefits
Reliable and up-to-date P&IDs, including complete as-built documentation and accurate plant registration
Reduced risk of errors during installation, modifications, and future process changes
Improved safety through clear visibility of critical process points and flow paths
Improved production efficiency and maintenance effectiveness through clear and accurate documentation
Enhanced reliability and traceability to support audits and quality assurance processes
Engineering Work Preparation
Work preparation forms the connection between engineering design and project execution. The objective is to develop a technically complete and executable plan, ensuring that installations are realized efficiently, safely, and in accordance with specifications. Through a structured approach, design decisions are translated into detailed material selections, components, and installation procedures, reducing risks during construction, commissioning, and operation.
Our Services
Creating and verifying detailed item lists and Bills of Materials (BOMs) for all process components and equipment
Validating P&IDs, connections, and material selections for technical feasibility and compliance with EHEDG requirements
Technical coordination between engineering, procurement, suppliers, and execution teams
Developing detailed construction and installation instructions, including dimensional requirements, tolerance checks, and insulation specifications
Identifying potential design and installation challenges, including piping routes, clearances, and component compatibility
Our approach
Our team starts by reviewing the functional design and existing P&IDs. We combine this input with project data, including technical specifications, supplier information, and production requirements. Potential scenarios such as alternative material selections, supply delays, and design changes are assessed and validated at an early stage. All results are captured in structured work preparation documents, providing all disciplines with a reliable basis for planning, coordination, and execution.
Customer benefits
Complete technical project preparation, including accurate and up-to-date material specifications, component lists, and documentation
Reduced risks during construction, installation, and commissioning activities
Improved reliability and operational continuity of production processes
Improved collaboration and alignment between engineering, procurement, suppliers, and execution teams
Comprehensive documentation supporting future maintenance, modifications, and expansion projects
Commissioning
Commissioning is the phase where engineering design and project execution come together. The objective is to bring installations, piping systems, tanks, and process systems into reliable operation in accordance with defined requirements and process standards. A structured commissioning process ensures that flow rates, pressures, temperatures, and other critical process parameters are verified and optimized, enabling safe and efficient production start-up. This expertise is essential for new installations, production expansions, and modifications to existing process systems.
Our Services
Performing functional tests on all system components to verify correct operation
Process start-up and optimization of setpoints to achieve reliable and efficient operation
Testing and verification of instrumentation, valves, pumps, and sensors to ensure correct functionality
Testing and validation of safety and control systems to ensure reliable operation
Identifying and resolving operational deviations, performance issues, and inefficiencies
Supporting process optimization and system fine-tuning to achieve optimal performance
Our approach
Our team follows a structured approach from engineering design through to full operation. We begin by reviewing technical documentation and P&IDs, followed by inspections and simulations to identify potential issues at an early stage. Functional testing is then performed, and the process is brought into operation in a controlled manner, with setpoints carefully determined and optimized. Operating scenarios and abnormal conditions are tested to verify system reliability and safety. Final validation of all systems and processes completes the commissioning phase, ensuring a safe and reliable production start-up.
Customer benefits
Reliable and efficient production with optimized and validated process parameters
Reduced risk of failures, product losses, and unsafe operating conditions
Optimization of process flows and energy consumption to improve overall process efficiency
Ensured safety and compliance through validated systems, including correctly functioning alarm and safety systems
Ensured installation reliability and operational continuity, minimizing maintenance requirements and unplanned downtime
Trouble Shooting
Troubleshooting focuses on the fast and effective resolution of process issues, ensuring that products meet specifications and installations operate reliably and efficiently.
The objective is to minimize production downtime, safeguard product quality, and maintain the reliability and performance of the installation.
Through a systematic analysis approach, root causes are identified and corrective actions are implemented to prevent future process disruptions.
Our Services
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Analyzing process data to identify causes of product quality deviations and performance issues
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Identifying root causes of extended CIP cycle times or ineffective cleaning performance
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Optimizing heat exchanger performance to resolve efficiency issues and improve process reliability
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Identifying energy losses and inefficient utility consumption within process systems
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Identifying and resolving recurring issues with valves, sensors, and instrumentation
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Performing scenario analyses and simulations to validate root causes and verify potential sources of process issues
Our approach
We follow a structured troubleshooting approach:
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Collecting relevant input, including process data, batch records, maintenance records, and inspection reports
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Problem analysis: performing root cause analysis and simulations to identify and validate underlying causes
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Validation: testing and evaluating solutions together with operators and engineering teams
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Implementation: optimizing process settings, equipment configurations, and operating procedures
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Follow-up: monitoring solution effectiveness and implementing measures to prevent recurrence
Customer benefits
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Restoring product quality and consistency when products deviate from defined specifications
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Optimization of CIP cycle times and ensuring effective cleaning of process systems
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Improved heat exchanger performance and optimized energy efficiency
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Reduction of recurring failures in valves, sensors, and other process equipment
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Improved safety and reliability of the installation
Process Optimization
Process optimization focuses on improving the efficiency, reliability, and overall performance of production processes. Through the analysis of existing installations and process data, bottlenecks are identified, such as pressure and flow limitations, product losses, and inefficient heat transfer. The objective is to maximize production efficiency while minimizing energy and water consumption and reducing cleaning times, without compromising safety, compliance, or product quality.
Our Services
Identifying bottlenecks in production and CIP processes to improve efficiency and reliability
Analysis of pressure losses and flow limitations in piping systems
Optimization of heat exchanger performance and energy efficiency
Reducing product losses through targeted process improvements and optimization
Evaluation of CIP cycle times and optimization of CIP systems
Developing and implementing technical solutions to reduce process inefficiencies and improve overall performance
Our approach
Our team starts by collecting process data and reviewing existing P&IDs, combined with production performance and energy consumption data. Simulations are performed to evaluate process scenarios, including pressure losses, flow behavior, and heat transfer performance. Based on these analyses, targeted improvements are developed and validated, including optimizations of piping systems, valves, heat exchangers, and CIP cycles. The optimization process considers operational continuity, safety requirements, and compliance with EHEDG guidelines.
Customer benefits
Improved production efficiency and reduced process cycle times
Reduced energy and water consumption through optimization of heating and CIP processes
Reduced product losses and enhanced process stability and reliability
Reduced CIP cycle times and improved cleaning efficiency
Preventing pressure and flow limitations that can cause process disruptions
Improved installation reliability, operational safety, and process performance
Process optimization delivers measurable technical value by making production processes more efficient, predictable, and reliable, directly supporting the continuity, safety, and performance of your operations.