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Endress+Hauser factory tour series: Transforming designs into reality

Martin Anklin, Head of R&D Department, and Benedikt Löffler, Quality Manager at Endress+Hauser Flow, take Manifold Times on a tour down the prototyping and production lines.

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Manifold Times gained exclusive access into the mass flowmeter (MFM) production factory of Reinach-based Endress+Hauser Flow in Switzerland during February. This will be the second in a series of five articles produced offering behind-the-scenes glimpses of the intricate process on what goes into perfecting MFMs.

The following are key takeaways from the tour to understand more about MFM design and production:

The conversion of ideas into reality is amongst the most challenging aspects of any business and Reinach-based mass flowmeter (MFM) manufacturer Endress+Hauser Flow exemplifies the Swiss ethos of detail and attention, learns Manifold Times.

Martin Anklin, Head of R&D Department at Endress+Hauser Flow, was keen to share details of how Endress+Hauser Flow factories around the world design and produce a significant amount of MFMs per year while maintaining the level of precision required by its custody transfer devices.

And it all starts with…

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Prototyping new MFMs

MFM applications are widely used in various industries such as maritime where the devices are responsible for measuring the bunker fuel and engine fuel consumption and more on an ocean-going vessel.

Market demand may call for prototyping of a new MFM design due to e.g. new custody transfer rules and the number of prototypes per MFM model will depend on the nominal diameter, otherwise known as internal line size in millimetres, as required by the project.

“Typically, when you have a small line size between DN 15 to 25 you’re very fast in making prototypes where a prototype and simulation can be done in parallel within a day,” informs Anklin.

“Experiments can be done overnight and depending on the results we can build a new prototype based on earlier findings [on the next day].

“But when it comes to bigger sizes like DN 80, 100 and 250 the number of prototypes is fewer, typically between two to three units due to increased cost and time required to build the bigger devices.

“After the final prototype is developed, the next step is to see if the quality is reproducible.”

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Technical industrialisation and ‘Kanban’

Prior to production, several considerations must be attended to ensure the produced meter has identical quality as the prototypes tested during development, said Anklin.

Amongst those are making sure the right tooling is available to build the MFM, and even the tools themselves undergo periodical inspection to ensure they are performing correctly.

“We do have several quality check gates in the production line to see if the meter is performing the way we expect, and the last gate is calibration to ensure its stable zero-point performance while passing all custody transfer requirements,” he explained.

Anklin also notes Endress+Hauser Flow utilising the ‘Kanban’ inventory control system. The production method originated from Japan and is being used to track production and order new shipments of parts and materials.

“We have a pre-production line for meters which are built without process connections and transmitters,” he said.

“When the customer places an order, we take the pre-fabricated sensor and “marry” it with the electronics, weld on the process connections and calibrate the device before being shipped.

“Our popular models are organised in a separate production line where Endress+Hauser Flow is able to complete order-to-shipments within 24 hours.”

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MFM Production – Swiss precision continues on the factory line

Benedikt Löffler, Quality Manager at Endress+Hauser Flow, was on hand to offer Manifold Times more details of pre and postproduction of the devices.

According to him, each Endress+Hauser MFM undergoes a water calibration to determine the calibration factor and to confirm the specified precision of up to 0.05% accuracy using traceable calibration rigs accredited by the Swiss Accreditation Service before leaving the factory.

Further, each Endress+Hauser MFM is equipped with sensors produced entirely in Switzerland.

“Every year, Endress+Hauser performs more than 30 certification audits to ensure products leaving the factory line are on-spec, but it doesn’t just stop here,” said Löffler.

“Suppliers have a high impact on our quality, so we maintain close relationships and perform audits with our suppliers with a focus on long-term relationship.

“A high variability of MFM products and human factors within the production line also mean training of workforce is a key element. We also support this by digitising production information to ensure traceability and facilitate access to information and by striving to retain our employees and their knowledge for many years.”

However, Swiss quality doesn’t stop after MFM devices leave the factory line, he says while stressing the importance of regular service by local third-party vendors and authorities to ensure Swiss quality being passed down the bunkering value chain.

“Compared to mechanical meters, the MFM has no so-called ‘moving parts’ which would alter the calibration factor. There is no need for replacing components of the measuring system over time. That means no frequent maintenance is required for MFMs,” he noted.

“But bunkering is a custody transfer process, and this means frequent verifications of the MFM system integrity must be defined by the local authority. This includes confirmation of the required measuring uncertainty and check that the system was not tampered.

“Measuring performance of a MFM can be confirmed on different levels of confidence starting with zero-point check up to Master Meter verification.

“With the built-in Heartbeat Technology, Endress+Hauser offers a unique way of MFM verification bridging the time between the officially scheduled verification intervals. This adds another layer of confidence.

“But ultimately, combining master meter verification with the frequent zero-point and Heartbeat Verification definitely increases the level of confidence”.

Related: Endress+Hauser factory tour series: Finer points of MFM design, explained by R&D

 

Photo credit: Endress+Hauser
Published: 5 August 2024

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Retrofit

DNV on key lessons learned from a 20,000 TEU methanol retrofit delivered by global partners

DNV demonstrated how complex methanol retrofits can be carried out in practice through a project involving COSCO Shipping, CHI Shanghai, MARIC, suppliers, and DNV.

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DNV on key lessons learned from 20,000 TEU methanol retrofit

Classification society DNV recently highlighted how complex methanol retrofits can be carried out in practice through a project involving COSCO Shipping, CHI Shanghai, MARIC, suppliers, and DNV. 

Its latest Maritime Impact article detailed challenges in design integration, construction, commissioning, and operations, while demonstrating how close collaboration and early planning support more efficient delivery and knowledge transfer: 

The world’s first methanol conversion project for a mega container carrier was completed at CHI‑Shanghai’s yard in September 2025. At nearly 400 metres in length and with a capacity of 20,000 TEU, the seven‑year‑old vessel became the first ship of its kind to be retrofitted to run on methanol. 

Delivered through close coordination between COSCO Shipping, CHI Shanghai, designers, suppliers, and DNV, and supported by a process of continuous learning, the project demonstrated that deep, first‑of‑a‑kind retrofits can be executed safely, on time, and at industrial scale.

Designing a methanol conversion for a megaship

The vessel’s fuel system, designed only for conventional fuels, required fundamental changes to enable safe and compliant methanol operation across propulsion, auxiliaries, storage, and safety systems.

The general design was developed by MARIC, while CHI Shanghai carried out the detailed engineering and served as EPC contractor. The scope included conversion of the ship’s MAN B&W 11S90 main engine and two of its four Wärtsilä auxiliary engines to dual‑fuel operation. In parallel, new methanol fuel tanks with a total capacity exceeding 15,000 cubic metres were installed forward of the engine room, together with new fuel preparation and supply systems.

Coordinating the complexity of retrofitting

Delivering this as a retrofit rather than a newbuild added complexity that is often underestimated. Existing structural arrangements could not simply be replaced, and new systems had to be integrated into confined spaces, requiring innovative construction sequences and tight interface management between suppliers. 

“This was a very complex project involving many parties, including engine makers, fuel system suppliers, and automation and safety specialists,” says Yan Hao, Commercial Director at CHI‑Shanghai. “It was also the first time all of these suppliers had worked together on a methanol retrofit of this scale. Coordination was critical.”

Note: The full article by DNV can be read here.

 

Photo credit: DNV and COSCO Shipping
Published: 15 June, 2026

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Wind-assisted

DNV on wind-assisted propulsion: Managing safety while regulation takes shape

Georgios Kasimatis explains how wind-assisted propulsion systems safety is already being managed through the ISM Code, class standards, and flag state engagement.

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DNV on wind-assisted propulsion: Managing safety while regulation takes shape

In this Maritime Impact article, published on Monday (8 June), Georgios Kasimatis, Director of Regulatory Affairs at classification society DNV, explained how wind-assisted propulsion systems (WAPS) safety is already being managed through the ISM Code, class standards, and flag state engagement. 

The article explored current operational practices, emerging IMO guidance, and what shipowners can expect as safety frameworks continue to evolve alongside wider adoption of the technology:

Wind-assisted propulsion systems (WAPS) have moved beyond pilot projects. Today, ships equipped with rotors, wings, and sails are trading globally, helping owners cut fuel consumption and emissions while responding to increasingly stringent greenhouse gas requirements. Yet this rapid operational uptake is unfolding faster than binding international regulation is being finalized. 

This creates a familiar but critical tension. The technology is already in service and increasing in scale across the global fleet, but the International Maritime Organization (IMO) is still developing harmonized safety guidance. For operators in the space, that gap can feel like uncertainty or risk. In reality, the regulatory signals around WAPS are becoming clearer, and safety processes are already in place through the International Safety Management (ISM) Code, flag state engagement, and classification standards.  

WAPS are now firmly on the IMO safety agenda 

At the IMO level, wind propulsion and wind-assisted power are now clearly on the safety agenda. The subcommittee on ship design and construction has been formally tasked with developing interim safety guidelines, supported by correspondence group work and progressing towards consideration by the maritime safety committee. While timelines at IMO can be revised, these guidelines are expected to be developed and finalized within the next three to four years.    

Importantly, these discussions are not happening in a vacuum. They sit within a wider IMO effort to ensure that new and emerging technologies and fuels are addressed within a broader, coherent safety framework. For WAPS, key developments so far have included their identification as a technology which requires dedicated safety standards, as well as recognition that existing instruments, such as SOLAS, COLREG, stability codes, and other navigational safety provisions, may not fully capture safety hazards specific to the technologies. 

The prevailing view in discussions to date is that risks appear manageable when systematically identified and controlled. Attention has centred on well-known risks that can be managed with the right design assumptions, operational controls, and human element safeguards. These include visibility and sensor performance, manoeuvrability and controllability, air draft and port interfaces, stability effects, extreme weather exposure, and crew competence.

Existing frameworks already manage WAPS risks 

Crucially, the absence of finalized IMO guidance does not mean that WAPS safety is unmanaged. Far from it. Today’s operational safety baseline rests on three pillars: flag state engagement, class approval using established technical standards, and – most fundamentally – the Safety Management System (SMS) under the ISM Code, a mandatory requirement under SOLAS Chapter IX. 

Class frameworks – including DNV’s technical standard (DNV-ST-0511) – already address core technical aspects, including structural integrity, fatigue, extreme wind loading, system integration, and operational limits. For installations designed and approved against these standards, future IMO guidance is more likely to bring harmonization than to trigger fundamental changes, and existing WAPS installations are therefore unlikely to be significantly affected.  

Where WAPS installations affect visibility in ways that touch SOLAS Chapter V/22, acceptance of equivalent arrangements remains a flag state decision, typically supported by class technical assessments. In practice, guidance such as DNV’s recommended practice for CCTV-based solutions (DNV-CG-0662) is commonly used to support these evaluations. 

Note: The full article by DNV can be read here

 

Photo credit: DNV
Published: 10 June, 2026

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Mass Flowmeter

Hong Kong backs MFM adoption with voluntary scheme to boost bunkering competitiveness

Hong Kong’s Marine Department launched the Quality Bunker Operator Scheme to encourage bunker operators to install and use mass flow meter systems on their bunker vessels.

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RESIZED EH dual mfm setup

Hong Kong’s Marine Department (MD) on Wednesday (3 June) launched the Quality Bunker Operator Scheme to encourage bunker operators to install and use mass flow meter systems (MFM systems) on their bunker vessels.

MD said the scheme aims to enhance Hong Kong’s bunkering service quality and the competitiveness of Hong Kong ports, thereby further consolidating Hong Kong’s position as an international maritime centre and a major bunkering port.

Under the Scheme, bunker operators of traditional maritime fuel and biodiesel that install and use MFM systems on their bunker vessels, with the MFM systems inspected and certified by an accredited body in accordance with the International Organization for Standardization’s ISO 22192 Standard or equivalent requirements, can apply to the MD for inclusion in the scheme’s “List of Quality Bunker Vessels”, provided they meet the relevant technical and operational requirements. 

Details of the bunker vessels successfully included in the List will be published on a dedicated page on the MD’s website for reference by shipping companies and relevant stakeholders.

Participation in the Scheme is voluntary. In addition to receiving recognition from the MD, participating bunker operators will benefit from enhanced corporate image and competitiveness through the adoption of MFM systems, thereby boosting customers’ confidence and helping to create new business opportunities.

 A spokesman for the MD, said: “As an international maritime centre supported by our country, Hong Kong has a strategic location adjacent to major international fairways. Coupled with years of development in marine fuel bunkering, Hong Kong possesses rich experience and talent in the field. For many years, Hong Kong has consistently ranked as the seventh-largest bunkering port globally, the second-largest in our country, and the largest in the Greater Bay Area, providing reliable and competitive fuel bunkering services to ocean-going vessels from around the world. 

“As the international shipping industry has an increasing demand for accuracy and transparency in bunkering services, service quality and measurement precision in bunkering operations have become important indicators of a bunkering port’s competitiveness. The Scheme will enhance bunkering accuracy and transparency, further enhancing the quality of Hong Kong’s bunkering services.

The spokesman added that comprehensive port services are one of Hong Kong’s key advantages as an international maritime centre.

“We will also mandate the use of MFM systems on all methanol bunker vessels this year to ensure that Hong Kong continues to provide high-quality bunkering services in the era of green maritime fuels.” 

Note: The application form for the Scheme can be found on the MD’s website. Interested bunker operators can download the application form from the website or contact the MD’s Green Maritime Fuel Team via email ([email protected]) for details.

 

Photo credit: Manifold Times
Published: 4 June, 2026

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