{"id":2405,"date":"2026-07-23T07:29:57","date_gmt":"2026-07-23T07:29:57","guid":{"rendered":"https:\/\/eurocalder.com\/industrial-processes-how-equipment-design-influences-plant\/"},"modified":"2026-10-15T14:52:52","modified_gmt":"2026-10-15T14:52:52","slug":"industrial-processes-how-equipment-design-influences-plant","status":"publish","type":"post","link":"https:\/\/eurocalder.com\/en\/news\/industrial-processes-how-equipment-design-influences-plant\/","title":{"rendered":"Industrial processes: types, stages and equipment in the plant"},"content":{"rendered":"

An industrial process<\/strong> is an organised set of physical, chemical, thermal or biological operations that transforms raw materials into intermediate or finished products. It includes stages such as storage, dosing, mixing, reaction, separation and quality control, and each one depends on equipment designed for the specific conditions of the product and the process.<\/p>\n

This article explains what an industrial process is, what types exist, how it is organised into stages and, above all, what equipment corresponds to each operation and what variables determine its design.<\/p>\n

What are industrial processes?<\/h2>\n

An industrial process is not the same as a production process or a unit operation. The industrial process is the complete set of activities that transforms a raw material<\/strong>. The production process is a broader concept, a set of activities that also includes planning, purchasing, control and distribution. A unit operation is an individual technical stage within the process: storing, mixing, heating, reacting, separating or conveying are distinct unit operations, each with a specific function, even though they form part of the same process. Many industrial companies organise their production by combining several of these operations.<\/p>\n

Types of industrial processes<\/h2>\n

Types of industrial processes and their production cycles are classified according to different axes, which should not be mixed with each other. Each production model requires different equipment sizing.<\/p>\n\n\n\n\n\n\n\n
Classification axis<\/strong><\/td>\nCategories<\/strong><\/td>\n<\/tr>\n
Nature of the transformation<\/td>\nPhysical, chemical, thermal, biological, mechanical, separation<\/td>\n<\/tr>\n
Production flow<\/td>\nContinuous, batch, semi-continuous<\/td>\n<\/tr>\n
Volume and configuration<\/td>\nMade-to-order, batch, series, mass<\/td>\n<\/tr>\n
Level of automation<\/td>\nManual, semi-automated, automated<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

A continuous process<\/strong> requires constant feed, stable flow rates and permanently connected equipment. A batch process<\/strong>, on the other hand, needs equipment capable of loading and unloading defined quantities, with cleaning between batches and individual traceability. A semi-continuous process<\/strong> combines continuous feed with periodic discharge, supported by buffer storage that synchronises both rates.<\/p>\n

Stages of an industrial process<\/h2>\n

An industrial process is a set of stages that can follow different sequences. The one that connects best with equipment design is: receipt of raw materials, initial storage, dosing, preparation or conditioning, transformation, separation or purification, finishing, final storage and dispatch. There is no single sequence valid for all industries<\/strong>: the order and the weight of each stage change according to the product and the sector.<\/p>\n

Unit operations and equipment<\/h2>\n

Each unit operation requires specific equipment and depends on particular variables that determine its design.<\/p>\n\n\n\n\n\n\n\n\n\n\n\n\n
Industrial operation<\/strong><\/td>\nTypical equipment<\/strong><\/td>\nMain variables<\/strong><\/td>\n<\/tr>\n
Liquid storage<\/td>\nVessel or tank<\/td>\nLevel, temperature, pressure<\/td>\n<\/tr>\n
Solid storage<\/td>\nSilo or hopper<\/td>\nWeight, moisture, level<\/td>\n<\/tr>\n
Mixing and homogenisation<\/td>\nReactor or agitated tank<\/td>\nSpeed, time, viscosity<\/td>\n<\/tr>\n
Reaction<\/td>\nIndustrial reactor<\/td>\nTemperature, pressure, time, pH<\/td>\n<\/tr>\n
Fermentation<\/td>\nFermenter<\/td>\nTemperature, oxygen, pressure<\/td>\n<\/tr>\n
Heating or cooling<\/td>\nHeat exchanger or jacketed equipment<\/td>\nTemperature, flow rate<\/td>\n<\/tr>\n
Fluid conveyance<\/td>\nPipework, valves and pumps<\/td>\nFlow rate, pressure, head loss<\/td>\n<\/tr>\n
Separation<\/td>\nFilter, settling tank or centrifuge<\/td>\nParticle size, density<\/td>\n<\/tr>\n
Dosing<\/td>\nHopper, vessel or weighing system<\/td>\nWeight, volume, flow rate<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

An industrial process does not depend solely on the order of its operations, but on each piece of equipment being suited to the product, the capacity, the pressure, the temperature, the viscosity, the corrosiveness and the applicable regulations.<\/strong><\/p>\n

At Eurocalder, we design and manufacture vessels and tanks<\/a>, industrial silos<\/a>, reactors<\/a> and heat exchangers<\/a> adapted to these variables, as well as pipework networks<\/a> for conveyance between operations.<\/p>\n

Variables to control in the design<\/h2>\n

Not all variables come into play in every process, but several directly determine the equipment:<\/p>\n\n\n\n\n\n\n\n\n\n\n
Variable<\/strong><\/td>\nDesign implication<\/strong><\/td>\n<\/tr>\n
Pressure<\/td>\nThickness, geometry and manufacturing code<\/td>\n<\/tr>\n
Temperature<\/td>\nMaterial, insulation and thermal system<\/td>\n<\/tr>\n
Corrosiveness<\/td>\nMaterial selection<\/td>\n<\/tr>\n
Viscosity<\/td>\nAgitation and pumping<\/td>\n<\/tr>\n
Capacity<\/td>\nVolume and dimensions<\/td>\n<\/tr>\n
Flow rate<\/td>\nDiameters, pumps and pipework<\/td>\n<\/tr>\n
Weight<\/td>\nStructure, supports and weighing system<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

The weight<\/strong> is controlled using load cells<\/a>. The documentary traceability<\/strong> is required by a certified quality management system. The accuracy of a process depends both on the physical equipment and on its integration with industrial control.<\/p>\n

Automation and control of industrial processes<\/h2>\n

These production systems rely on basic instrumentation that includes level, temperature, pressure and flow sensors, as well as weighing systems. The actuating elements – valves, pumps, agitators, heating or cooling systems – execute the commands generated by a PLC or a SCADA system, which also logs alarms, manufacturing recipes and traceability. Implementing automated processes does not replace good mechanical design: a well-programmed control system does not fix incorrectly sized equipment<\/strong>.<\/p>\n

Examples of industrial processes by sector<\/h3>\n

These process examples show how technical requirements change by sector:<\/p>\n