Sie suchen auf: {{ keyword }}
Introduction
Morssinkhof, a major player in the recycling sector, developed a completely new industrial installation for washing recycled plastic granulate. As part of this development, they needed complete, CE-compliant documentation to support safe and efficient operation in an industrial process environment. Because the installation contained multiple sections, each composed of machinery and supplier components, they required a partner capable of structuring a large volume of diverse documents and translating them into clear procedures for daily operation and maintenance.
Morssinkhof engaged INSTRKTIV to create the complete set of operator and maintenance procedures for the installation, organise the underlying supplier documentation, and support CE compliance for the whole process line. This case study shows how INSTRKTIV helped to bring clarity and structure to a technically complex project in the process industry.
The situation before the project
Before INSTRKTIV became involved, no coherent documentation existed for the new installation. Morssinkhof had only a folder with component documents provided by suppliers, written in different formats and languages. There were no consolidated procedures for operating the installation, and no overview of required maintenance tasks. As Erwin, our leading technical writer involved in the project, noted, there was simply “a folder with a lot of documentation from the machine parts”, and the request was to turn this into clear procedures and a complete maintenance overview
Because an external engineering agency newly designed the installation, the project started from scratch. INSTRKTIV needed to gather all available supplier documents, understand the engineering design and convert fragmented technical information into structured and usable documentation.
Project challenges
The project presented several challenges typical of the process industry. The installation contained multiple interconnected sections, labelled 100, 200, 300 and so on, each with its own components and maintenance requirements. The quantity of source documentation was substantial, and the quality varied significantly between suppliers. Some suppliers provided detailed maintenance procedures, others offered minimal information, and some did not specify maintenance intervals at all.
“The quality range of the supply documents varies a lot” and the team had to sort and interpret a very high number of documents before drafting unified procedures"
- Erwin Bergs, lead technical writer
Another complexity came from the fact that supplier documents were written in Dutch and English. To avoid errors in future translations and maintain clarity, INSTRKTIV decided to reference supplier documents by document name and chapter number rather than rewriting long sections from them.
Despite these challenges, Morssinkhof wanted a single, consistent document that described how to operate the entire installation and how technical staff should perform maintenance safely and in line with CE obligations.
Why Morssinkhof sought external support
Morssinkhof needed an experienced partner for three main reasons. First, they required CE-compliant documentation and lacked internal expertise to create such material. Second, the engineering team lacked time because they were focused on building and commissioning the installation. Third, they needed support from specialists who understand risk assessments and how to translate risk reduction measures into operational procedures.
"Morssinkhof was looking for a partner with experience in both documentation
and risk mitigation within industrial processes"
- Ferry Vermeulen, Founder at INSTRKTIV BV
INSTRKTIV’s approach
INSTRKTIV began by analysing the installation's structure. Because the installation was divided into clearly numbered sections, this provided a logical basis for structuring the operator and maintenance procedures. INSTRKTIV created an overview that shows which supplier documents apply to which part of the installation. Some components were applied to multiple sections, others to just one, and this mapping formed the backbone of the final documentation.
For the operational procedures, INSTRKTIV conducted a site survey and walked through the installation from beginning to end. This made it possible to document each operational stage, from start-up to shut-down, and to create clear step-by-step descriptions of how operators should use the installation.
“We went from beginning to end through all the operating stages of the machine when
preparing the operational procedures"
- Erwin Bergs, lead technical writer
In terms of safety and compliance, INSTRKTIV used the Machinery Directive and relevant standards, such as ISO 20607, as guidelines for the structure and content of the procedures. Risk reduction measures from the customer’s risk assessment were incorporated, and the documentation was checked against CE obligations to ensure completeness.
Although AI tools were used to speed up the extraction of maintenance information from supplier documents, all material was manually verified. This was necessary because supplier documents often contained cross-references that automated tools could not reliably interpret. INSTRKTIV ensured human oversight at every stage to maintain accuracy.
Finally, to overcome inconsistent or incomplete supplier documentation, INSTRKTIV chose a referencing strategy. Instead of rewriting supplier content, the procedures included references to specific documents and chapter numbers. This avoided translation issues and ensured that updates to supplier documentation would not accidentally invalidate parts of the Morssinkhof documentation.
Results and impact
The completed documentation provided Morssinkhof with a set of clear, structured procedures for operating and maintaining the installation. Because the installation was already running during the writing phase, the documentation not only supported the CE compliance check but also enabled the customer to carry out maintenance consistently and safely.
They could finally do the maintenance on the installation, using the structured procedures provided by INSTRKTIV.
- Erwin Bergs, lead technical writer
The final documentation describes all tasks required for daily operation, from startup to shutdown. It also includes detailed maintenance procedures for technical staff. This supports audits, certification processes and the long-term safe use of the installation. The procedures are structured to help Morssinkhof keep the installation running safely and for an extended period of time.
The project also strengthened Morssinkhof's market position. With professionally documented operation and maintenance procedures, they can now present the installation with greater confidence in commercial contexts.
Conclusion
This project is a strong example of INSTRKTIV’s capabilities within the process industry. It demonstrates how INSTRKTIV can turn an extensive collection of diverse documents into clear and consistent procedures for operators and technical staff. It also shows how INSTRKTIV handles complex industrial installations that combine in-house engineering with supplier components, variable documentation quality and demanding CE requirements. It highlights how INSTRKTIV has the expertise to make a manual that can help anyone who has to deal with the machine work safely.
Recycling plastic granulate is a necessary industrial process, and by supporting Morssinkhof, INSTRKTIV contributed to both safety and sustainability in this sector. The project illustrates how structured documentation, grounded in technical and regulatory expertise, can play a decisive role in the successful operation of modern industrial installations.
Are you curious to learn how we can support your projects?
