STEP 1: Concept

Every project starts with a base level concept with varying degrees of detail. From napkin drawing to fully developed machine spec, we take your concept and make it a reality.  At this stage of the process our project engineers help you:

  • Evaluate the feasibility of your project
  • Provide detailed feedback on your concept
  • Propose alternative conceptual solutions

STEP 2: Engineered Custom Solutions

Once the concept of your system is finalized, this is the most critical stage of any project we are involved with.  Our engineers carefully complete the due-diligence up front to identify:

  • How will the machine work?

We provide conceptual solutions with diagrams and drawings as required.

  • How long will it take to build your machine?

We provide projected delivery based on current assumptions and requirements.

How much will it cost?

Bernal provides a ball park number to see if it makes sense to proceed. Budget numbers can be provided as we move forward in the project then a final, firm quotation can be completed that includes all of the requirements to meet your needs.

STEP 3: Machine Design

The detail of the machine design builds upon the Concept and Quotation stages of the project by integrating standard designs, unique designs, commercial components, electrical systems and overall system design that constitute a final machine design included in this phase are:

  • 3-D modeling
  • Force calculations
  • Detailed component selection
  • Finalized machine design
  • Sign-off by customer

STEP 4: Electrical Design

Your Electrical specifications, applicable safety standards and approved components will be integrated into a unique Electrical Automation package. Bernal’s engineering team will work with you throughout the entire process to meet your needs and requirements.

  • Determine overall Automation design & Strategy
  • Complete Electrical design
  • Determine best operating platform for the application
  • Complete programming and operator interface
  • Data collection

STEP 5: Machine Fabrication

Your machine will then be fabricated to meet specifications. This stage includes:

  • Structural fabrication
  • Mechanical fabrication
  • Electrical wiring
  • Piping/tubing
  • Instrumentation
  • Component assembly
  • Finishing
  • Guarding

STEP 6: Factory Testing and Approval

As the custom machine builder, the machines that leave our facility are fully tested operating at required specifications.  We welcome our customers to our facility to be an integral part of this process. Our start-up and commissioning process includes:

  • FAT testing
  • Operator training
  • Punch list resolution
  • Maintenance training
  • Shipping
  • Continuous Improvement

STEP 7: Installation & Site Acceptance

  • Installation Supervision
  • Operation & Maintenance Manuals provided
  • Factory Testing, Commissioning
  • SAT per customer requirements
  • Continuous Improvement
  • Operator Training