• Upgrade line for pre-assembled garages
  • Prefabricated garages in production
  • Semi-automated production line for prefabricated garages

Zapf set itself the goal to make their garage production plant in Dülmen one of the biggest and most modern production plants for precast concrete garages in Europe.

At the end of the year 2015, Zapf placed an order with Prilhofer Consulting to develop a concept for the expansion and to support the project implementation and acceptance. The project aimed at joining the garage production in the existing hall in Dülmen and relocating existing garage shutterings of the plant in Herne. The concept had to be developed minimizing modifications at the existing halls and minimizing additions of new halls.

First, a logistics concept and a concept for the production workflow were created. Subsequently, Prilhofer Consulting advised Zapf during the tendering phase for the carousel system, as well as for the control system of the upgraded production. Finally, we supported the monitoring of plans and the coordination of design in the project, as well as installation, start-up and acceptance of machines and plants.

The upgraded garage production plant in Dülmen is in operation since the end of 2016.

Zapf decided to collaborate with Prilhofer Consulting on the expansion of their garage production plant in Dülmen. They aimed at covering “grey areas” and all the interfaces of the project. In addition to that, costs should be decreased and planning should be optimized by specifying and clearly defining the project. Moreover, we were responsible for the crosschecking and control of the time schedule in order to avoid delays in the project.

Adam Zapf founded the construction company Zapf in 1904. In 1961, the company underwent a change from being a construction company to being a precast concrete factory and expanded continuously in the following decades.

Since 2011, Zapf is the German market leader in the field of garage production and exports to European neighbor countries.

At the moment, the company has more than 600 employees and a turnover of nearly 100 million Euros. All the products are manufactured at four locations in Germany: Weidenberg and Baar-Ebenhausen in Bavaria, Neuenburg in Baden-Württemberg, as well as Dülmen in North Rhine-Westphalia. The company belongs to the French LNC group, located in Paris.