Production of a New Aggregate Washing Drum

• Customer: Vápenka Vitošov (in cooperation with MELKOV)
• Project Location: PME Production Plant, Přerov / Vápenka Vitošov
• Project Period: 01–06 / 2026
• Key Benefit: Complete replacement of a critical piece of equipment     after 40 years of operation, without original documentation and with     minimal downtime.

1. Assignment and Initial Situation: The Challenge ofMissing Documentation

For the end customer Vápenka Vitošov, in cooperation with MELKOV, wedelivered a project involving the complete manufacture of a new aggregatewasher. The new unit was designed to replace an existing machine that hadoperated reliably for approximately 40 years but had reached the end of itsservice life.

Key technical challenge: Sufficient technicaldocumentation for the original washer was unavailable. Without accuratemanufacturing data, it was impossible to design and manufacture a replacementunit that would fit perfectly with the existing process equipment andstructural interfaces at the Vápenka Vitošov plant. The partners thereforesought a capable manufacturer able to manage the engineering process fromscratch and assume full responsibility for dimensional accuracy.

Photo 1: Original heavy-dutyaggregate washing drum operating at the Vápenka Vitošov plant, for whichmanufacturing documentation was unavailable.

2. PME Solution: Creating a Digital Twin Through 3DScanning

At PME, we proposed a modern and efficient approach that eliminated therisk of errors and avoided unnecessary dismantling of the original machineduring measurement.

Directly within the demanding operating environment of the limestone plant,we carried out professional 3D scanning of the existing aggregate washer. Thisenabled us to capture not only the machine itself, but more importantly allcritical connection points to the surrounding process technology withmillimetre-level accuracy.

Based on the scanned data, our engineering teamprepared:

• Detailed 3D scanning report
• Complete new manufacturing and engineering documentation.
• Accurate production documentation for fabrication in our workshops.
• Dimensional inspection reports and NDT reports for welded joints.

This stepsuccessfully replaced the missing historical documentation and transformed theequipment into a modern digital and physical model.

Photo 2: Digitalisation in practice. Our specialist measures the key guiderings of the washer using a high-precision handheld 3D scanner.

Photo 3: Deployment of a stationary long-range 3D scanner mounted on atripod to capture the overall geometry and surrounding process interfaces.

Photo 3a–3b: 3D model of the washer.

3. Manufacturing and Assembly: Everything Under OneRoof at PME

Following approval of the engineering documentation, production commencedin our manufacturing facilities. Maximum emphasis was placed on weld quality,geometric accuracy and flawless integration with the inlet and outlet chutes ofthe process line.

Efficient workshop assembly of internal components: Aspart of the project, the washing drum was fitted with a specialised internalassembly supplied by the customer. To eliminate complex and time-consumingon-site installation at the limestone plant, we installed this assemblydirectly into the new washing drum at PME prior to final shipment.

Photo 4: View of the washer internals. The bladearrangement and internal lining were fully assembled and welded in PMEworkshops.

The machine was also equipped with a screeningsection, complete inlet and outlet assemblies, guide rings and additionalinternal components. As a result, the unit left the PME production facility asa fully completed and assembled machine.

Photo 5: Final appearance of the newly manufacturedaggregate washer from PME. The equipment is fitted with all functionalcomponents, including guide rings and inlet assemblies.

4. Results and Key Benefits for the Customer

Thanks to our comprehensive approach, the customer received a new, modernand highly reliable machine that fully meets current operational requirementswhile fitting perfectly into the location of the original equipment.

• Zero Risk of Interference: 3D scanning ensured     perfect integration with the existing process technology. 

• Significant Reduction in Downtime: Because the     machine was delivered fully assembled, including all internal components,     lengthy on-site assembly was eliminated. Following delivery, the limestone     plant was able to install the unit directly into the process line without     delays.
• Complete Engineering Service: A turnkey     solution from measurement and documentation through manufacturing and     final delivery.
• Reliable Long-Term Operation: The new equipment     provides confidence in trouble-free operation for decades to come.

Photo 6: Safe transportation to thefinal destination. The fully assembled process unit leaves our facility readyfor direct installation into the Vápenka Vitošov production line.

Conclusion

This project clearly demonstrates PME’s expertise in reverse engineeringand heavy industrial manufacturing. The modernization project for VápenkaVitošov showed how large-scale process equipment can be successfully reproducedand upgraded even when original documentation is unavailable. We take fullresponsibility for the entire process, save our partners valuable time andminimise operational risks.

Planning a plant modernisation project or looking toreplace obsolete equipment? Contact us and we will be pleased to provide aturnkey solution tailored to your needs.

‍