Engineering Process:
From Concept to
Complete Custom Machinery
At Bernal, we transform your initial ideas into fully operational, high-performance machines. Our engineering process is designed to guide each project from a base concept to a finished, rigorously tested machine ready for production. Through careful planning, precise design, and dedicated support, we collaborate with you at every step—from feasibility assessment and custom solutions to fabrication and installation. With Bernal’s commitment to quality and precision, we deliver custom machines that meet the highest standards for functionality, safety, and efficiency.
Engineering Process: Turning Concepts into Custom, High-Performance Machines
Step 1: Concept Development
Every project begins with a concept—whether it’s a simple sketch or a fully developed machine specification. Our team works with you to bring your ideas to life. During this phase, our project engineers:
- Assess the feasibility of your project
- Offer detailed feedback on your initial ideas
- Suggest alternative conceptual solutions for improved functionality
Step 2: Custom Engineering Solutions
Once your concept is finalized, we move into a critical phase of in-depth engineering. Here, we perform rigorous due diligence to identify key project elements:
- Machine Functionality: We develop detailed diagrams and drawings to illustrate how your machine will operate
- Timeline: Based on the current project scope, we provide an estimated delivery timeframe
- Budget: An initial estimate is provided to ensure project viability. As the design progresses, we refine this estimate into a firm quotation
Step 3: Machine Design
Building upon the concept and engineering groundwork, our team moves into detailed machine design, incorporating standard and custom components. This phase includes:
- 3-D modeling for visual and functional accuracy
- Force calculations to ensure performance integrity
- Precise selection of components
- Finalized design with client sign-off
Step 4: Electrical Design
Our engineering team integrates your electrical specifications and safety standards into a comprehensive automation package. During this phase, we:
- Define the overall automation strategy
- Complete the full electrical design
- Select the optimal operating platform for your application
- Complete programming, interface design, and data collection functionality
Step 5: Machine Fabrication
Your machine is built to exact specifications, focusing on precision and quality. This stage includes:
- Structural and mechanical fabrication
- Electrical wiring and component assembly
- Piping and tubing for integrated systems
- Finishing and safetyguarding for operational reliability
Step 6: Factory Testing and Approval
Our facility thoroughly tests each machine to ensure it operates at the required specifications. Clients are encouraged to participate in this process. Our rigorous testing and approval process includes:
- FAT (Factory Acceptance Testing) for functionality and reliability
- Operator and maintenance training
- Addressing any remaining punch list items
- Preparing the machine for shipment
Step 7: Installation and Site Acceptance
Our team oversees the installation and final acceptance upon delivery to ensure a seamless transition to your facility. This final phase includes:
- Installation supervision
- Comprehensive operation and maintenance manuals
- SAT (Site Acceptance Testing) to customer specifications
- Continued operator training and support
Each phase of our engineering process is designed to provide you with a reliable, high-performance custom machine that meets your specific needs and industry standards. Bernal is dedicated to precision, quality, and continuous improvement from concept to commissioning.
Engineering Process: Turning Concepts into Custom, High-Performance Machines
Step 1
Concept Development
Every project begins with a concept—whether it’s a simple sketch or a fully developed machine specification. Our team works with you to bring your ideas to life. During this phase, our project engineers:
- Assess the feasibility of your project
- Offer detailed feedback on your initial ideas
- Suggest alternative conceptual solutions for improved functionality
Step 2
Custom Engineering Solutions
Once your concept is finalized, we move into a critical phase of in-depth engineering. Here, we perform rigorous due diligence to identify key project elements:
- Machine Functionality: We develop detailed diagrams and drawings to illustrate how your machine will operate
- Timeline: Based on the current project scope, we provide an estimated delivery timeframe
- Budget: An initial estimate is provided to ensure project viability. As the design progresses, we refine this estimate into a firm quotation
Step 3
Machine Design
Building upon the concept and engineering groundwork, our team moves into detailed machine design, incorporating standard and custom components. This phase includes:
- 3-D modeling for visual and functional accuracy
- Force calculations to ensure performance integrity
- Precise selection of components
- Finalized design with client sign-off
Step 4
Electrical Design
Our engineering team integrates your electrical specifications and safety standards into a comprehensive automation package. During this phase, we:
- Define the overall automation strategy
- Complete the full electrical design
- Select the optimal operating platform for your application
- Complete programming, interface design, and data collection functionality
Step 5
Machine Fabrication
Your machine is built to exact specifications, focusing on precision and quality. This stage includes:
- Structural and mechanical fabrication
- Electrical wiring and component assembly
- Piping and tubing for integrated systems
- Finishing and safetyguarding for operational reliability
Step 6
Factory Testing and Approval
Our facility thoroughly tests each machine to ensure it operates at the required specifications. Clients are encouraged to participate in this process. Our rigorous testing and approval process includes:
- FAT (Factory Acceptance Testing) for functionality and reliability
- Operator and maintenance training
- Addressing any remaining punch list items
- Preparing the machine for shipment
Step 7
Installation and Site Acceptance
Our team oversees the installation and final acceptance upon delivery to ensure a seamless transition to your facility. This final phase includes:
- Installation supervision
- Comprehensive operation and maintenance manuals
- SAT (Site Acceptance Testing) to customer specifications
- Continued operator training and support
Each phase of our engineering process is designed to provide you with a reliable, high-performance custom machine that meets your specific needs and industry standards. Bernal is dedicated to precision, quality, and continuous improvement from concept to commissioning.