Case studies.
Real projects where engineering solves bottlenecks, improves ergonomics and ensures operational continuity.
Sheet metal transport and handling system
Context
Coachbuilding plant. The manual process of loading sheet metal onto the cutting table created bottlenecks and severe ergonomic risks for operators due to material weight.
Challenge
Significantly reduce physical effort and cycle times at the cutting station, ensuring ergonomic safety at the workstation and speeding up machine feeding.
Solution
Design and implementation of a custom pneumatic vacuum system for automated transfer and precise feeding of sheet metal to the cutting table.
Project role
Mechanical Design and Engineering
Tools
Autodesk Inventor, Pneumatic Calculation, Structural Analysis
Pipe bundle storage system
Context
Traditional floor-level storage of pipe bundles consumed excessive usable plant area, hindered inventory traceability and complicated forklift maneuvers.
Challenge
Optimize space through vertical storage while enabling fast and clear identification of the different pipe sizes to speed up production.
Solution
Design of a robust front-loading rack equipped with an integrated moving carriage system. Bundles are loaded at the front and moved inward safely and ergonomically.
Project role
Structural and Mechanical Engineering
Tools
Autodesk Inventor, FEM Structural Analysis, AutoCAD
Mezzanine design for workstations
Context
The plant needed to add new assembly and inspection stations, but the floor-level layout was saturated, making horizontal expansion impossible without disrupting circulation routes.
Challenge
Optimize the interior volume of the industrial building by enabling a new safe operating level without interrupting the lower production line.
Solution
Design and structural analysis of a custom steel mezzanine. Engineering included load validation, industrial access stairways and layout of the new workstations to maximize usable space.
Project role
Structural Engineering
Tools
Autodesk Advance Steel, Structural Calculation, AutoCAD
Design of a 500-liter industrial processing kettle
Context
Equipment development for a final client in the food sector requiring thermal mixing and strict temperature control across continuous production batches.
Challenge
Design a large-capacity (500 L) kettle ensuring homogeneous heating via burners and an efficient agitation system, in strict compliance with food sanitation regulations (stainless steel).
Solution
Complete detailed engineering of a gas-heated kettle. An agitation shaft with scrapers adapted to the bottom geometry was designed and burner thermal distribution was optimized.
Project role
Process Engineering and Mechanical Design
Tools
Autodesk Inventor, Thermal Calculation, Sanitary Design
Design of a base plate grinding machine
Context
The installation of critical rotating process equipment showed premature component wear caused by irregularities in the original structural mounting.
Challenge
Design a portable mechanical solution able to grind the support plates directly in the field, achieving perfect flatness and coplanarity for equipment installation.
Solution
Engineering and development of a custom portable grinding machine. The guide system, feed carriages and cutting drive were designed to ensure correct base plate flatness in situ.
Project role
Mechanical and Precision Engineering
Tools
Autodesk Inventor, Geometric Tolerancing (GD&T), AutoCAD
Assessment and fabrication of an access ladder for a hydraulic excavator
Context
The original cab access system of a mining hydraulic shovel (Hitachi) suffered severe damage during operation, compromising safe operator access and equipment availability.
Challenge
Carry out the on-site assessment and modeling for the fabrication of a functional, integrated replacement that fits the existing mounting points while delivering greater structural robustness for the mining environment.
Solution
Fabrication of a heavy-duty articulated ladder. The project covered everything from the field assessment to the production drawings required to replicate the original model, restoring safe access to the equipment.
Project role
Assessment and modeling
Tools
Autodesk Inventor, Field Survey, AutoCAD
Design of a steam exhaust header
Context
Operations at the Talara Refinery required safe, controlled and efficient management of residual steam coming from oil process units.
Challenge
Design and size an exhaust manifold (header) able to withstand demanding pressure and temperature conditions, ensuring safe steam relief without compromising the integrity of adjacent lines.
Solution
Mechanical and piping engineering for the fabrication of a residual steam relief header. The design strictly complied with high-pressure standards and complete construction drawings were produced.
Project role
Piping and Pressure Equipment Engineering
Tools
Autodesk Inventor, ASME Codes, AutoCAD