Brewing Success

Belgium-based machine builder IMA relies on modularisation to quickly supply its customers. Thanks to EPLAN Experience, IMA’s processes run even more efficiently today – something its customers appreciate, including Belgium’s Moortgat Brewery. IMA, headquartered in Houthalen-Helchteren, Belgium, has become a leading player in the machine-building industry, having completed approximately four thousand projects to date in all areas of the industry, both at home and abroad. From research and pre-engineering, through mechanical design, production, assembly and installation, all the way to successful commissioning, the company offers its customers a single source for complete machine development. The modernisation of existing machines is another of the company’s core strengths. With its three business units – Tooling, Automation and Prototyping – IMA covers a broad range of specific products and services. The modular approach the machine builder takes to the company’s day-to-day work has become a matter of course.

Focus on Modularisation

The development of individual modules as part of a project has become a standard procedure at IMA. The reason: an increased focus on quality set against cost and time savings puts extremely high pressure on the machine builder’s customers, making quick action a necessity. As IMA Sales Director Joris Ceyssens explains, “Because of this contradiction, we cannot start a project from scratch anymore, especially when it comes to developing prototypes. The entire supply chain is under pressure. This is why we have increasingly begun to build our projects modularly and mechatronically, backed by our experience. We’re reaping the benefits of this approach today.” This modular approach covers the company’s entire scope of activities. IMA has developed numerous machines for its loyal customers over the past 29 years, and retrofitting and revamping older machines is now an important part of IMA’s services portfolio. With norms and standards that are continuously being reformed, it’s important for customers to continually update and adapt the machines they already have. In this context, the company has also seen a significant increase in the numbers of requests to combine various machines over the past several years.

Engineering Culture 4.0

In response to rising customer demand, IMA also expanded its Automation business unit. Along with investment in the recruitment of specialised colleagues, this also called for the implementation of new technologies in work processes, for which IMA turned to the expertise of EPLAN. Joris Ceyssens explains: “We took inspiration from the EPLAN Expert Dialogues to implement new technologies in our work processes. This is where we learned to look beyond solely mechanical modularisation. For example, the importance of structuring and standardisation of the modules emerged. Together with an EPLAN expert, we looked at how we could use this for our applications. Our hardware engineers went to EPLAN for training.” Their efforts paid off: today IMA has found the right balance when combining the modularisation, structuring and standardisation of its projects. This machine builder has been able to shorten turnaround times and work even more efficiently. The new working method was an enormous change for IMA and impacted the entire engineering culture within the company. But it offers a solid foundation to better integrate all the engineering domains and machines, even within customers’ IT infrastructure. Joris Ceyssens: “Our new approach created fundamental change within the company. It’s made us far more flexible and efficient than before, and this enables both us and our customers to remain competitive. Industry 4.0 is not an empty ‘container concept’, but a vision that is integrated into the daily operation of our business.”

Mechatronics Concept

One important customer to benefit from the machine builder’s more efficient approach has been Moortgat Brewery in Belgium, which is especially well known for its Duvel beer. Moortgat was faced with a logistical challenge: they needed to make optimum use of the available space for refrigeration. The solution: IMA developed a specific, fully automated pallet-stacking machine, leading to a 25 per cent increase in capacity. IMA used various applications during development, including precise positioning, vacuum techniques, a custom-developed XZ manipulator with long range, and servo technology. But there was even more: using the new knowledge gained from EPLAN’s expertise, IMA developed a complete mechatronics concept: from mechanical design, through electric and pneumatic engineering, to software. “For Moortgat, aside from the entire design process, we even took care of manufacturing, assembly and safety. Thanks to EPLAN, our employees had the necessary know-how to achieve optimum efficiency for the brewery,” Joris Ceyssens says before adding with a laugh, “and now Moortgat can once again focus on what it does best – brewing beer.”