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Turnkey Plant Solutions

Project Planning

From first concept to running production

Building a new sanitaryware plant or expanding an existing one is decided long before the first machine arrives. CASTIMO supports ceramic manufacturers through every stage of a turnkey project: from the initial feasibility study and capacity planning, through factory layout and process engineering, to installation, commissioning and the ramp-up to stable production.

Developed in accordance with German engineering standards and backed by more than a decade of experience in high pressure casting, our project planning connects all production stages into one efficient, reliable line.

Phase 1

Analysis & feasibility

Phase 2

Plant design & engineering

Phase 3

Realization

Phase 4

Commissioning & ramp-up

Phase 5

Operation & after-sales

01

Analysis & feasibility

Analyse & Machbarkeit

Every successful plant starts with an honest assessment. Before any equipment is specified, we analyze whether and how your project can reach its targets under real conditions.

Feasibility study: evaluation of site, raw material supply, slip quality, energy availability and skilled labor in your region.
Capacity planning: from target output to a concrete machine park — number of casting lines, mould requirements and shift models.
Product portfolio consulting: which articles (WCs, washbasins, cisterns, tableware) are economically produced with high pressure casting, and where conventional casting remains the better choice.

02

Plant design & engineering

Werksplanung & Engineering

The plant concept translates the feasibility results into a factory that works as one continuous line from slip preparation to final inspection.

Factory layout & material flow: 2D/3D layouts with optimized routing from slip house to dispatch, designed for short distances and future expansion.
Process design: casting, drying, glazing, firing and inspection engineered as an integrated production line rather than isolated machines.
Utilities planning: slip preparation, compressed air, water treatment, energy demand and waste heat recovery.
Investment planning: CAPEX/OPEX calculation, ROI analysis and staged expansion concepts — for example, starting with one ANKA casting line and scaling up in defined steps.

03

Realization

Realisierung

During implementation, CASTIMO acts as your single point of responsibility coordinating deliveries, suppliers and interfaces so the project stays on schedule.

Project management: milestone planning from order to production start, with transparent reporting at every stage.
Supplier & interface coordination: integration of third-party equipment such as kilns, glazing robots and conveyor technology into one consistent plant concept.
Delivery & installation: worldwide logistics, professional installation and supervision by experienced CASTIMO engineers.

04

Commissioning & ramp-up

Inbetriebnahme & Ramp-up

A plant is only finished when it produces at target quality. We stay on site until it does.

Commissioning & trial production: systematic start-up of all systems, process parameter optimization and first casting trials with your slip and your moulds.
Operator & mould-shop training: hands-on training for machine operators and mould personnel — the foundation of stable long-term quality.
Ramp-up support: accompaniment through the ramp-up phase until target capacity, cycle times and reject rates are reliably achieved.

05

Operation & after-sales

Betrieb & After-Sales

For CASTIMO, production start is not the end of the project it is the beginning of a long-term partnership that keeps your plant performing.

Mould supply: continuous delivery of porous resin moulds and support from our in-house mould making service.
Mould care: CASTIDUR and CASTINOVA chemicals for maximum mould lifetime and consistent casting results.
Spare parts & technical support: fast supply of wear and spare parts for ANKA machines, plus remote and on-site technical assistance.

Your Partner for Integrated Sanitaryware Production

With over 40 years of experience in mould design, machine engineering and production, and over 15 years of specialization in porous resin manufacturing, Castimo provides fully integrated turnkey solutions from a single source — including both new and professionally refurbished equipment. Supported by German project management standards and a strong international partner network, we ensure efficient project execution and reliable long-term performance.

Plan Your Turnkey Plant

Tell us your products, target capacity and site new facility, expansion or in-house mould shop and we propose the right complete solution.

The complete production system from one source

Engineering, equipment, moulds, installation, commissioning and ramp-up one contract, one responsibility, one contact person. From the first feasibility study to stable series production.

Project phases

Porous Resin

High-porosity resin systems for High Pressure Slip Casting over 100,000 casting cycles per mould.

Systems & products

Mould Care & Paint

Cleaning, care and mould paints for maximum mould lifetime and consistent casting results.

Systems & products

Reckli

RECKLI products for model and mould production clean mould release and flawless plaster moulds with fast setting and long service life.

Systems & products

Mould Service

From model development to serial moulds our own mould shop, not a subcontractor.

Systems & products

CNC Service

CNC machining for sanitaryware, tableware and technical ceramics from porous resin blocks to individual machining requests. We also offer our CNC service for projects outside the ceramics industry.

Material Preparation

Slip and glaze preparation, storage, screening and weighing the basis for constant casting quality.

Systems & products

Casting Systems & Machines

Traditional bench casting and high pressure casting machines of the ANKA series dimensioned to your output.

Systems & products

Drying Systems

A smart drying solution with digital process integration uniform, optimised drying that minimises cracking, warping and surface imperfections.

Systems & products

Glazing Systems

Glaze application, retouching, foot wiping and syphon glazing from manual cabins to carousel lines.

Systems & products

Firing Systems

Firing is integrated into the overall layout to ensure smooth material flow and compatibility with the defined production concept kiln type, capacity and kiln-car concept are dimensioned to the casting output.

Systems & products

Automation & Robotics

Casting, glazing and logistic robots added where they pay off, not everywhere.

Systems & products

Internal Logistics

Transport and conveyor systems connecting every stage of the line.

Systems & products

Project Planning

Feasibility, capacity concept and factory layout the earlier we are involved, the more efficient your plant becomes.

Systems & products

Laboratory & Testing

Laboratory equipment and functional testing for running production.

Systems & products

Refurbished Equipment

Overhauled machines where the budget decides available equipment changes continuously, information on request.

Systems & products

Service & Spare Parts

Spare parts, modernization and training after handover.

Systems & products

Porous Resin

High-porosity resin systems for High Pressure Slip Casting over 100,000 casting cycles per mould.

Systems & products

Mould Care & Paint

Cleaning, care and mould paints for maximum mould lifetime and consistent casting results.

Systems & products

Reckli

RECKLI products for model and mould production clean mould release and flawless plaster moulds with fast setting and long service life.

Systems & products

Mould Service

From model development to serial moulds our own mould shop, not a subcontractor.

Systems & products

CNC Service

CNC machining for sanitaryware, tableware and technical ceramics from porous resin blocks to individual machining requests. We also offer our CNC service for projects outside the ceramics industry.

Turnkey Plant Solutions

Project Planning

From first concept to running production

Phase 1

Analysis & feasibility

Phase 2

Plant design & engineering

Phase 3

Realization

Phase 4

Commissioning & ramp-up

Phase 5

Operation & after-sales

01

Analysis & feasibility

02

Plant design & engineering

03

Realization

04

Commissioning & ramp-up

05

Operation & after-sales

Your Partner for Integrated Sanitaryware Production

Plan Your Turnkey Plant

Products & Solutions

The complete production system from one source

Porous Resin

Mould Care & Paint

Reckli

Mould Service

CNC Service

Material Preparation

Casting Systems & Machines

Drying Systems

Glazing Systems

Firing Systems

Automation & Robotics

Internal Logistics

Project Planning​

Laboratory & Testing ​

Refurbished Equipment ​

Service & Spare Parts

Porous Resin

Mould Care & Paint

Reckli

Mould Service

CNC Service

Project Planning

Laboratory & Testing

Refurbished Equipment