BEFER Introduces a Tailored Circulation System for Special precast Components

“Our goal was to make things as easy and flexible as possible, without the long wait times. The best part was that we achieved this while also improving safety, thanks to the Avermann underfloor system working seamlessly with RIB One Prefab’s smart touchscreen controls.”

Volker Weidemann, Managing Director, BEFER

70 years of experience – a foundation for innovation

BEFER GmbH, a midsized precast concrete components manufacturer and a subsidiary of Richard Schulz Tiefbau GmbH, specializes in special precast elements like elevator shafts, staircases, and solid walls. With deep technical expertise and a focus on quality, BEFER serves both public and private construction projects, and is recognized as a reliable partner for complex precast needs.

When standard processes hit their limit

To redefine quality, efficiency, and safety, BEFER planned a complete rebuild of its production facility. The old configuration offered little room for innovation, especially in flexible custom precast production and workplace safety. The core requirement was a control system that adapts to BEFER’s workflow, not the other way around.

More visibility, less downtime

BEFER partnered with RIB One Prefab Automation and Avermann to build a fully customized control concept. RIB developed an HMI/SCADA touchscreen interface, enabling flexible routing across 28 workstations. Everything, from design to commissioning and early production, was delivered in close collaboration with BEFER.

BEFER leads the way in special precast component production

Since opening in 2023, BEFER’s new plant has enabled highly flexible processes, particularly for custom parts. Thanks to a 4×7 pallet grid-based routing system, workstations and process times can be dynamically scheduled. This increases system utilization, minimizes downtime, and enables product-specific pacing. The intuitive touchscreen boosts transparency and team ownership.

A new production concept for special precast parts

BEFER’s focus is on complex, consulting-heavy precast parts. As the share of special components grew, the traditional fixed-cycles system became too rigid. Custom parts with varied process times demanded a flexible and user-friendly solution. BEFER’s answer: a new facility with a new control concept built entirely to their requirements.

Flexibility over fixed cycles

At the core of the new plant is an innovative floor-level pallet system that enables individually planned routes between stations. Unlike conventional production lines tied to rigid intervals, this system adapts dynamically with each pallet following a path tailored to the specific needs of the component.

This breakthrough approach called for an entirely new control philosophy. In collaboration with long-time machinery partner Avermann, BEFER selected RIB One Prefab Automation—not only for its flexibility, but for its ability to seamlessly integrate with both hardware and safety systems, ensuring smooth, intelligent coordination across the entire operation.

Custom-built control interface – co-developed with BEFER

RIB and BEFER collaborated closely to design a tailored HMI/SCADA interface that meets the specific demands of BEFER’s operations. A functional demo enabled hands-on testing, real-time feedback, and continuous refinement, resulting in a user-friendly, highly practical solution shaped directly by real-world use on the factory floor.

Volker Weidemann, Managing Director, explains, “We were clear from the start: operating the system should be as intuitive as a child using an iPhone. The touchscreen interface allows every worker to interact with the system directly and easily.”

Prioritizing safety and ease of work

Worker safety was a key design principle from the start. The plant features a fully floor-integrated transfer system, eliminating tripping hazards and raised installations for a cleaner, safer workspace. In partnership with RIB, BEFER implemented a robust safety protocol, anchored by a modern safety PLC that ensures secure, compliant operations.

While the floor-level setup posed some commissioning challenges, particularly around component accessibility, these were quickly and efficiently resolved through close coordination between teams.

Reduced downtime and improved accuracy

Since early 2023, BEFER has been running the new line at approximately 80% utilization, despite the complexity of special precast elements. Flexible routing reduces downtime and allows demand-driven control of pallets. Setup times have dropped significantly, and dimensional accuracy has improved.

Weidemann summarizes the impact, “The new control concept gives us the freedom to choose the most efficient path. Three taps on the screen and the system knows where the pallet needs to go. Behind the scenes, everything is set up automatically by the underfloor system.”

This mix of usability, flexibility, and automation has boosted efficiency and reduced downtime, without compromising safety. BEFER can now adapt workflows on the fly, from rearranging stations to spontaneous routing changes. RIB One Prefab’s modular system also provides a future-ready foundation for expansions and automation.