Custom Engineering Projects

A standard product catalogue solves many problems, but in the real world of heavy industry every facility has its own specific constraints. Custom engineering comes into play in the following situations:

• The customer's material does not fit the standard equipment portfolio (e.g., unusual density, corrosive chemistry, very high temperature).

• The site geometry does not accept standard solutions (e.g., tight space, unusual incline, multi-floor traversal).

• The process line cannot be solved with a combination of standard equipment; a special composite machine is required.

• The capacity of an existing line is insufficient and it needs to be modernised.

In each of these situations, the TMD GRUP engineering office develops a from-scratch design together with the customer.

The custom engineering process begins with understanding the customer's problem and goals. The engineering office produces the following outputs:

• Problem definition and performance criteria (capacity, energy, size, noise, safety).

• Alternative concept solutions — multiple approaches are proposed and their trade-offs shown.

• Theoretical calculations for the selected concept — mass balance, motor power, stress calculation, heat transfer, etc.

• Concept-validation meeting with the customer — direction approval is taken before the design is locked.

Avoiding mistakes at this stage is critical; the cost of subsequent stages is much higher.

After the concept is approved, detailed 3D modelling begins. TMD GRUP uses SolidWorks and Inventor:

• 3D solid models of all components — every part from a bolt to a motor cover is modelled.

• Assembly models — how components connect to each other.

• Collision checking — whether moving parts will collide during operation is checked in software.

• Compatibility with the customer's facility in 3D — placed into the plant BIM model if needed; assembly corridors and service access are verified.

The output of this stage is a 3D model set with the precision needed to be sent to production.

For parts that carry critical loads or operate at high speed, static calculations are not enough; the stress distribution under real operating conditions must be modelled. TMD GRUP applies finite element analysis (FEA) using ANSYS or SolidWorks Simulation:

• Static analysis — stress and deformation under constant load.

• Dynamic analysis — behaviour under variable load, vibration, impact.

• Thermal analysis — temperature distribution and thermal stress.

• Fatigue analysis — crack-initiation risk under repeated loading.

FEA results verify the design's safety factor and indicate areas that need to be reinforced if necessary.

In some custom engineering projects, prototype production is done before moving to final production:

• Full-scale prototype — for validating a new machine concept.

• Scaled prototype — for testing a specific stage in a large facility at smaller scale.

• Field test — the prototype is installed at the customer site, run with actual material; performance data is collected.

• Fine-tuning — final design corrections based on field data.

This approach significantly reduces the risk of surprises when moving to final production. It is a critical step especially for innovative designs.

Custom engineering is not only about from-scratch design. Modernisation and capacity expansion of an existing facility are also within TMD GRUP's scope:

• Retrofit of old machines — with modern motors, sensors, control systems.

• Capacity expansion — 20-40% more capacity through changes on the existing line.

• Efficiency improvements — changes that reduce energy consumption or maintenance frequency.

• Environmental compliance revisions — improvements in dust, noise and waste control to meet new regulations.

Every modernisation project starts with measuring the existing facility, identifying bottlenecks and understanding the customer's operational goals.

At the end of a TMD GRUP custom engineering project, the customer receives: