Process Plants
Where precision is essential—and reliability makes all the difference.
Complex production processes require intelligent control strategies, transparent workflows, and a deep understanding of the respective industry. A particular challenge is the large-scale nature of modern process plants—from extensive piping networks to a multitude of measurement points, valves, and control loops that must interact reliably across distributed systems. Gefeba supports such large-scale projects from planning through commissioning to long-term support, ensuring that even extensive, multi-site facilities can be operated safely, systematically, and efficiently.
Areas of Application
Chemistry
Chemical production facilities operate in an environment where requirements change frequently and on short notice: new formulations, varying raw materials, revised production targets, or necessary adjustments to process lines. Flexibility is therefore not just an added benefit—it is a fundamental prerequisite for cost-effective operation. At the same time, high safety standards must be maintained, and complex process flows must be controlled transparently and reliably at all times. Particularly challenging are fast changeover times, flexibly expandable control systems, and modular automation architectures capable of supporting a wide variety of product lines—without compromising safety, traceability, or documentation. Gefeba develops scalable solutions for these needs that support dynamic process requirements, simplify plant retrofits, and efficiently integrate both batch and continuous processes.
Services at a Glance:
- Automation of Batch and Continuous Process Systems in Accordance with ISA-S88
- Migration of Existing Systems (PCS7, DeltaV, ABB Freelance)
- PLT Engineering and Integration of Common Fieldbus Systems
- ATEX-compliant control cabinet construction, FAT, SAT, and documentation
- Modularization Using PLT Containers for Flexible System Expansions
Food
Food production requires the highest standards of hygiene, absolute reproducibility, and a consistently clear process logic—because even the smallest deviations can affect quality, safety, and entire batches. In addition, systems must comply with strict legal requirements and integrate seamlessly with cleaning and inspection processes. Gefeba develops solutions that combine quality, efficiency, and safe production at every level.
Typical systems:
- Automation of Hygiene-Critical Areas
- Design and Manufacture of Switchgear with a Hygienic Design
- Batch Processes and Recipe Management
- CIP/SIP Systems for Cleaning and Sterilization
- Energy and Quality Monitoring
Petrochemicals
Petrochemical plants are characterized by continuous processes, high temperatures, and safety requirements. Switchgear and EMR technology in potentially explosive atmospheres are particularly challenging, as every component must meet the strictest standards and every detail of the design must be fully traceable. Our specially certified employees provide expert advice that is safe, compliant with standards, and proven in practice—from design and documentation through to acceptance testing—and develop modular, scalable solutions that operate reliably and safely over the long term, even in Ex zones.
Our Services:
- Automation of Reactor and Refinery Processes
- SIL- and PL-compliant safety technology
- ATEX-Compliant Control Cabinet Construction
- Control Systems for Storage, Pumping, and Loading Facilities
Pharmaceuticals
Pharmaceutical facilities are subject to strict regulatory requirements—from GMP guidelines and qualification documentation to full traceability at every stage of the process. Every change, every module, and every process step must be reproducible, documented, and auditable. The requirements for automation systems, validation processes, and data management quality are correspondingly high. To meet these requirements, Gefeba relies on qualified, proven building blocks and standardized process models that cover the entire lifecycle of a module—from the creation of qualified functional building blocks to defined test procedures. Our modules are designed to integrate seamlessly into existing GMP systems, be flexibly expanded, and be efficiently validated.
Skills:
- GMP-compliant automation in accordance with GAMP guidelines
- Use of qualified function modules and standardized test protocols
- Support with validation, IQ/OQ, and audit preparation
- Batch systems, formula management, and complete traceability
- Monitoring and Documentation-Compliant Control Systems
Skills in Process Engineering
Scalable control and management systems for large-scale production processes.
Flexible automation for batch and continuous chemical processing plants.
Automation for food and pharmaceutical processes that meet the highest quality standards.
Standard-compliant automation for petrochemical plants and ATEX environments.
Increase efficiency.
Secure processes.
Shaping the future.
Maximize the efficiency of your processes with our automation solutions. We provide precision technology for demanding industrial applications.
Process Engineering
Our projects demonstrate how complex production processes can be controlled safely, efficiently, and consistently—even in large-scale plants and for sensitive applications.