{"id":60,"date":"2026-11-06T19:06:37","date_gmt":"2026-11-06T11:06:37","guid":{"rendered":"https:\/\/kerkepm.com\/projects\/turnkey\/"},"modified":"2026-11-11T13:12:59","modified_gmt":"2026-11-11T05:12:59","slug":"turnkey","status":"publish","type":"page","link":"https:\/\/kerkepm.com\/es\/projects\/turnkey\/","title":{"rendered":"Turnkey Projects"},"content":{"rendered":"<div class=\"k3\">\n<div class=\"wrap\"><div class=\"crumbs\"><a href=\"\/\">Home<\/a><span>\/<\/span><a href=\"\/projects\/\">Projects<\/a><span>\/<\/span>Turnkey<\/div><\/div><div class=\"wrap\"><div class=\"hero\">\n<p class=\"kicker\">Projects \u00b7 Turnkey<\/p>\n<h1>Turnkey extrusion plant: one scope, one schedule<\/h1>\n<p class=\"dek\">A turnkey extrusion plant is a contract where one party owns the layout, the machine list, the installation and the first good pellet. The value is not the equipment list \u2014 it is that nobody can point at somebody else when commissioning slips, and that the process window and the starting formulation arrive with the machines.<\/p>\n<div class=\"byline\"><div><b>Scope<\/b> layout to handover<\/div><div><b>Process<\/b> window + recipe<\/div><div><b>Commissioning<\/b> 1 week line \/ 3 weeks plant<\/div><div><b>FAT<\/b> on site or by video<\/div><\/div>\n<\/div><\/div>\n<div class=\"wrap\"><figure class=\"banner vhero\">\n<button class=\"plcover\" type=\"button\" data-vid=\"iBMgmu9fOLk\" aria-label=\"Play the Kerke factory tour video on this page\"><img decoding=\"async\" src=\"\/wp-content\/uploads\/2026\/11\/vid-projects-hero.webp\" alt=\"Kerke factory tour video \u2014 twin screw extruder manufacturing and assembly floor\" width=\"1200\" height=\"675\" fetchpriority=\"high\"><span class=\"plplay\" aria-hidden=\"true\"><\/span><\/button>\n<\/figure><\/div>\n<div class=\"wrap\"><div class=\"grid\"><main>\n<nav class=\"wp-block-rank-math-toc-block k3-toc\" aria-label=\"On this page\"><b>On this page:<\/b><a href=\"#s1\">Quick answer<\/a><a href=\"#s2\">What it includes<\/a><a href=\"#s3\">Six stages<\/a><a href=\"#s4\">Process &amp; formulation<\/a><a href=\"#s5\">What the customer provides<\/a><a href=\"#s6\">When turnkey is the wrong choice<\/a><\/nav>\n<section class=\"qa\" id=\"answer\"><h2 id=\"s1\">Quick answer<\/h2><p>A turnkey extrusion plant covers <strong>layout, machine list, manufacture, factory acceptance test, shipment, installation supervision, commissioning, the process window and the starting formulation<\/strong> \u2014 from a single pelletizing line to a full plant with feeding, compounding, drying and packing. You get the temperature profile, screw configuration, screw speed \/ output curve and a formulation written in percentages, not just a machine that runs. Commissioning is typically <strong>1 week for one line and 3 weeks for a full plant<\/strong>.<\/p><\/section>\n<div class=\"stats\"><div class=\"stat\"><b>1<\/b><span>contract, one responsible party<\/span><\/div><div class=\"stat\"><b>3 weeks<\/b><span>plant commissioning<\/span><\/div><div class=\"stat\"><b>FAT<\/b><span>before shipment<\/span><\/div><div class=\"stat\"><b>6<\/b><span>stages, each signed off<\/span><\/div><\/div>\n\n<h2 class=\"sec\" id=\"s2\">What a turnkey extrusion plant includes<\/h2>\n<p class=\"lead\">Six stages, each with a deliverable the customer signs off: requirement, design, manufacture, factory acceptance test, shipment, commissioning. The deliverable at the end is not a machine list \u2014 it is a plant that produces pellets to the agreed specification, with the process window and the formulation documented, and the customer's own operators running it.<\/p>\n<p>The scope boundary is written down before the order. Utilities, foundations, local labour, inbound freight and installation materials normally sit with the customer; machines, drawings, <b>process parameters, formulation support<\/b>, supervision, training and the commissioning report sit with us. Anything that crosses the line is named in the contract rather than discovered on site.<\/p>\n\n<h2 class=\"sec\" id=\"s3\">Six stages<\/h2>\n<div class=\"tw\"><table><caption><b>Table 1.<\/b> Stage, deliverable and what the customer provides.<\/caption>\n<thead><tr><th scope=\"col\">Stage<\/th><th scope=\"col\">What we do<\/th><th scope=\"col\">What you provide<\/th><\/tr><\/thead>\n<tbody>\n<tr><td><b>Requirement<\/b><\/td><td>Material, output, pellet standard, voltage, current recipe and budget review<\/td><td>Material samples, target specification, existing recipe if any<\/td><\/tr>\n<tr><td><b>Design<\/b><\/td><td>3D layout, screw configuration, process window, formulation start point, electrical drawings<\/td><td>Building drawing, column grid, power capacity<\/td><\/tr>\n<tr><td><b>Manufacture<\/b><\/td><td>Machining, assembly, 24 h gearbox run-in, loaded test<\/td><td>Deposit, drawing approval<\/td><\/tr>\n<tr><td><b>FAT<\/b><\/td><td>No-load and loaded test, pellet samples, video<\/td><td>Attendance on site or by video<\/td><\/tr>\n<tr><td><b>Shipment<\/b><\/td><td>Sea-worthy packing, documentation, CE where required<\/td><td>Shipping instructions<\/td><\/tr>\n<tr><td><b>Commissioning<\/b><\/td><td>Installation supervision, recipe tuning on site, training, handover<\/td><td>Utilities, local labour<\/td><\/tr>\n<\/tbody><\/table><\/div>\n<p>The design stage is where a turnkey project is won or lost: a layout that ignores the column grid or the available steam pressure produces a plant that runs at 70% of its quoted output and blames the extruder. The <a href=\"\/company\/factory\/\">factory<\/a> handles manufacture and FAT.<\/p>\n\n<h2 class=\"sec\" id=\"s4\">Processing technology and formulation are part of the scope<\/h2>\n<p>Half of a turnkey plant is hardware; the other half is knowing exactly what to put through it. So two documents travel with the line \u2014 the <b>process window<\/b> and the <b>starting formulation<\/b> \u2014 and both are written in numbers a shift leader can set on the panel.<\/p>\n<div class=\"tw\"><table><caption><b>Table 2.<\/b> What is handed over with the line, beyond the equipment.<\/caption>\n<thead><tr><th scope=\"col\">Document<\/th><th scope=\"col\">What it contains<\/th><\/tr><\/thead>\n<tbody>\n<tr><td><b>Formulation start point<\/b><\/td><td>Filler or reinforcement loading %, carrier resin grade and MFI, coupling agent \/ lubricant \/ stabiliser dosage, target moisture \u2014 as percentages on a 100 kg batch, not as &#8220;add as required&#8221;.<\/td><\/tr>\n<tr><td><b>Process window<\/b><\/td><td>Barrel temperature profile zone by zone, screw speed against the output curve, vacuum level, die and cutter settings, plus the limits where pellet quality starts to fall.<\/td><\/tr>\n<tr><td><b>Screw configuration drawing<\/b><\/td><td>Conveying, kneading and mixing elements in order, with the reason each block is there \u2014 so a later change is a decision rather than a guess.<\/td><\/tr>\n<tr><td><b>Trial and FAT report<\/b><\/td><td>Pellets made from the customer&#8217;s own material, with measured output, MFI, dispersion or filler content, and moisture.<\/td><\/tr>\n<\/tbody><\/table><\/div>\n<p>Formulation support usually means one of three things: matching a recipe the buyer already runs elsewhere, adapting it to a different filler grade or carrier resin, or starting from a specification (&#8220;40% talc, 8 kJ\/m\u00b2 notched, 6 g\/10 min&#8221;) where we propose the starting point and the trial decides. The machine is not sold and the recipe left as the buyer&#8217;s problem \u2014 the first good pellet is part of the contract.<\/p>\n<p>Two limits worth stating up front. Proprietary additives stay the customer&#8217;s IP: the recipe is handled under NDA and does not travel to another customer. And a formulation that works on the lab line still has to be re-tuned on the production line, because residence time and shear history change with screw diameter \u2014 which is what the commissioning week is for. Material-side detail sits on <a href=\"\/applications\/\">lines by application<\/a>.<\/p>\n\n<h2 class=\"sec\" id=\"s5\">What the customer provides<\/h2>\n<ul>\n<li><b>Building drawing<\/b> with column grid, clear height and floor loading \u2014 the layout cannot be drawn without it.<\/li>\n<li><b>Power capacity<\/b> at the point of connection, and the voltage and frequency actually delivered.<\/li>\n<li><b>Utilities<\/b>: water quality, pressure and temperature; compressed air; steam where the process needs it.<\/li>\n<li><b>Material samples<\/b> early enough for a trial \u2014 3\u20137 days before the configuration is frozen.<\/li>\n<li><b>A named project contact<\/b> who can approve drawings within the agreed window.<\/li>\n<\/ul>\n<p>Most schedule slippage in a turnkey extrusion plant traces back to one of those five items arriving late, not to machine building.<\/p>\n\n<h2 class=\"sec\" id=\"s6\">When turnkey is the wrong choice<\/h2>\n<p>If you already run a compounding plant with your own maintenance team, buying a line and integrating it yourself is usually cheaper and faster \u2014 a turnkey contract pays for coordination you do not need. Turnkey earns its premium when the plant is new, when several machines have to share one feeding and packing system, or when the buyer has no engineer who can own commissioning. The <a href=\"\/cases\/\">case studies<\/a> show both patterns; the material-side scope is on <a href=\"\/applications\/\">lines by application<\/a>.<\/p>\n<p>Start with the material and the target output: <a href=\"\/get-a-quote\/\">the quotation form<\/a> asks for both, and the reply states which stage of the six we would start from.<\/p>\n<p class=\"k3-rel\"><b>Reference:<\/b> <a href=\"https:\/\/en.wikipedia.org\/wiki\/Acceptance_testing\" target=\"_blank\" rel=\"noopener\">Wikipedia: Acceptance testing<\/a><\/p>\n<h2 class=\"sec\" id=\"faq\">FAQ<\/h2><details><summary>What does a turnkey scope include?<\/summary><p>Layout, machines, auxiliary equipment, installation, commissioning and operator training, plus the process window and starting formulation for your material.<\/p><\/details><details><summary>Who does the civil works and foundations?<\/summary><p>The customer; Kerke supplies the foundation drawings and supervises the machine installation so the interfaces stay unambiguous.<\/p><\/details><details><summary>How long does a full plant take?<\/summary><p>60-120 days from order depending on the number of lines, with each line wet-run tested before it leaves the works.<\/p><\/details><script type=\"application\/ld+json\">{\"@context\": \"https:\/\/schema.org\", \"@type\": \"FAQPage\", \"mainEntity\": [{\"@type\": \"Question\", \"name\": \"What does a turnkey scope include?\", \"acceptedAnswer\": {\"@type\": \"Answer\", \"text\": \"Layout, machines, auxiliary equipment, installation, commissioning and operator training, plus the process window and starting formulation for your material.\"}}, {\"@type\": \"Question\", \"name\": \"Who does the civil works and foundations?\", \"acceptedAnswer\": {\"@type\": \"Answer\", \"text\": \"The customer; 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The value is not the equipment list \u2014 it is that nobody can point at somebody else when commissioning slips, and [&#8230;]\n","protected":false},"author":0,"featured_media":0,"parent":58,"menu_order":42,"comment_status":"closed","ping_status":"closed","template":"page-blank.php","meta":{"footnotes":""},"application":[],"app_group":[],"class_list":["post-60","page","type-page","status-publish","hentry"],"_links":{"self":[{"href":"https:\/\/kerkepm.com\/es\/wp-json\/wp\/v2\/pages\/60","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/kerkepm.com\/es\/wp-json\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/kerkepm.com\/es\/wp-json\/wp\/v2\/types\/page"}],"replies":[{"embeddable":true,"href":"https:\/\/kerkepm.com\/es\/wp-json\/wp\/v2\/comments?post=60"}],"version-history":[{"count":0,"href":"https:\/\/kerkepm.com\/es\/wp-json\/wp\/v2\/pages\/60\/revisions"}],"up":[{"embeddable":true,"href":"https:\/\/kerkepm.com\/es\/wp-json\/wp\/v2\/pages\/58"}],"wp:attachment":[{"href":"https:\/\/kerkepm.com\/es\/wp-json\/wp\/v2\/media?parent=60"}],"wp:term":[{"taxonomy":"application","embeddable":true,"href":"https:\/\/kerkepm.com\/es\/wp-json\/wp\/v2\/application?post=60"},{"taxonomy":"app_group","embeddable":true,"href":"https:\/\/kerkepm.com\/es\/wp-json\/wp\/v2\/app_group?post=60"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}